Exercises - Configure lean manufacturing
Before you begin
To get the most benefit from these exercises, we recommend that you have the standard sample data available in Supply Chain Management that is installed by using Lifecycle Services.
Exercise - Create a value stream
After defining and mapping the lean manufacturing value stream for the USMF company, you must create the value stream in Supply Chain Management.
Go to Production control > Setup > Lean production flow > Value streams.
Select New in the Action Pane to create a new value stream.
Enter the following details for the new value stream:
Name: SeaLeanVS
Search name: SeaLeanVS
Manager: Jodi Christiansen
Select Save.
Exercise - Create a production flow
As the production (shop) floor supervisor, you have a logical grouping of work cell capacity with similar behavior in capacity load for the work cells that are used to model the Car Speaker production flow.
You must create a new production flow (SeaPFModel) to model the process of painting the covers for the car speakers. The capacity and load of the production flow will be measured in quantities of product that are produced (throughput).
The cycle for this production flow will be defined as one day, the number of days that are used in automatic planning (EPE cycle is 1 day). The Add method of kanban scheduling will be used if no capacity is available during the required periods; the planning period type is Day and the planning time fence is 10.
Go to Production control > Setup > Lean production flow > Production flow models.
Select New in the Action Pane.
In the Production flow model field, enter SeaPFModel.
In the Model type field, enter Throughput.
In the EPE Cycle in the Days field, enter 1.
In the Planning period type field, select Day.
In the Planning time fence field, enter 10.
In the Capacity shortage reaction drop-down menu, select Postpone.
Select Save.
Create a production flow
You must also create a production flow version for the USMF eBook production flow and set up the takt and cycle times as part of the configuration.
Details for the production flow:
| Field | Details |
|---|---|
| Name | eBookProdFlow |
| Description | eBook Production Flow |
| Legal entity | USMF |
| Value stream | SeaLeanVS |
| Production group | 10 |
| Per cycle unit of measure | pcs |
| Quantity per cycle | 1 |
| Average takt time | 1 |
| Minimum takt time | 1 |
| Maximum takt time | 2 |
| Period for actual cycle time (days) | 1 |
Go to Production control > Setup > Lean production flow > Production flows.
Select New on the Action Pane. A new production flow record is created.
In the Name field, enter eBookProdFlow.
In the Description field, enter eBook Production Flow.
In the Legal entity field, select USMF.
In the Value stream field, select SeaLeanVS.
In the Production group field, select 10.
Select Save.
On the Versions FastTab, select Add.
Select OK.
Configure the takt requirements for the new production flow version
Expand the Versions.
Under the Versions FastTab, in the Per cycle unit of measure field select pcs.
In the Quantity per cycle field, enter 1.
In the Average takt time field, enter 1.
Expand the Version details.
In the Minimum takt time field, enter 1.
In the Maximum takt time field, enter 2.
In the Period for actual cycle time (days) field, enter 1.
Select Save on the Action Pane.
Observe that the Plan status field, in the Versions FastTab is set to Draft.
Close all pages.
Exercise - Create a process activity
A new eBook stylus is being developed to complement the eBook kits that are sold at USMF. The stylus is purchased from an outside vendor and configured at USMF. A process activity is needed to configure the stylus and place it in stock for use elsewhere.
Details for the process activity:
| Field | Details |
|---|---|
| Name | Transfer Activity |
| Process quantity | 10 pcs |
| Operating unit | LeanProduction |
| Work cell | 1260 |
Go to Production Control > Setup > Lean Production Flows > Production flows.
Open the Mid Range Speaker 2 PF production flow.
On the Versions FastTab, select the Activities button.
Select the Create new plan activity button at the top.
Select Next.
Enter Transfer Activity in the Name field.
Enter 10 in the Process quantity field.
In the Unit drop-down list, select pcs.
In the Operating unit drop-down list, select LeanProduction.
Select Next.
Set the Update on hand on receipt option to Yes.
Select 1260 in the Replenishing field.
Select Finished product in the Product type field.
Select Next.
Select 13 in the Warehouse under Transfer from location.
Select 13 in the Location field under Transfer from location.
For the Transfer to location, select 22 in the Warehouse field.
Select location 01-01-2-1 in the Location field.
Select Shipper in the Freighted by field.
Select Next.
Select the Queue time after record.
Enter 4 in the Time field.
Select hr in the Time unit field.
Enter 10 in the Per quantity field.
Select the Runtime record.
Enter 2 in the Time field.
Select hr in the Time unit field.
Enter 10 in the Per quantity field.
Select Next.
Select Finish.
Select Save on the Action Pane
Exercise - Configure process and transfer
A new car speaker remote is being developed to complement the car speaker kits that are sold at Contoso. The CarSpeakProdFlow production flow needs to be amended to include a transfer activity to move the configured remote to the Electrical Component warehouse.
Details for production flow transfer activity:
| Field | Details |
|---|---|
| Name | RemoteTransfer |
| Process quantity | 10 |
| Operating unit | SeaLeanVS |
| Replenishing resource group | 1250 |
| Update on hand on receipt | Yes |
| Update on hand on pick | No |
| Transfer to | warehouse 61, location Output |
| Freighted by | Shipper |
| Runtime | 1 min per 25 pcs |
Deactivate the current production flow version
Go to Production Control > Setup > Lean production flow > Production flows.
Open the Standard speaker assembly production flow.
On the Versions FastTab, select version 1.
Select Deactivate.
Select OK. The Plan status changes to Draft.
Create a new transfer activity
On the Versions FastTab, select Activities. The Production flow activities page opens.
Select Create new plan activity on the Action Pane.
Select Next.
Enter RemoteTransfer in the Name field.
In the Activity type drop-down list, select Transfer.
Enter 10 in the Process quantity field.
In the Unit drop-down list, select pcs.
In the Operating unit drop-down list, select SeaLeanVS.
Select Next. The Create transfer activity page opens.
In the Replenishing drop-down list, select 1250.
Set the Update on hand on receipt check box to Yes.
Set the Update on hand on pick check box to No.
In the Product type field, select Finished product.
Select Next. The Assign transfer locations page opens.
In the Transfer to location group, in the Warehouse drop-down list, select 61.
In the Location drop-down list, select the first location listed: 01A01R1S1B.
In the Freighted by drop-down list, select Shipper.
Select Next. The Assign activity time page opens.
In the Time field for the Runtime row, enter 1.
In the adjacent Time unit drop-down list, select min.
In the Per quantity field, enter 25 pcs.
Select Next. The Confirm selection page opens.
Select Finish. The wizard closes and a new production flow activity appears in the list.
Select Save on the Action Pane.
Create the predecessor and successor relationship between the process and transfer activity with no constraints
Highlight the RemoteTransfer activity and on the Predecessors tab, select the Add predecessor link.
Select the Predecessor Activity of Cabinet assembly.
Enter the Cycle time ratio of 1.
Select the OK button.
Highlight the RemoteTransfer activity and on the Successors tab, select the Add successor link.
Select the Successor Activity of Replenish L83.
Enter the Cycle time ratio of 1.
Select the OK button.
Close the Production flow activities page.
On the Versions FastTab, select the Activation > Activate menu button. [!NOTE] You may receive an error when trying to activate. If this is the case, go to the RemoteTransfer activity under the Activities page and select Activity details in the Action Pane. From there, make sure that the Freighted by field in the Transfer details FastTab is set to Recipient.
Select OK. The Plan status changes to Active.
Exercise - Create activity relations
Pierre needs to revise the Mid-Range Speaker 2 PF production flow to have the Transfer_W12_to_W11 activity succeeded by the Process_Activity_1 activity.
Details for production flow transfer activity relations:
| Field | Details |
|---|---|
| Constraint | 1 hour |
| Cycle time ratio | 2 |
Add a successor to the production flow activity
Go to Production control > Setup > Lean production flow > Production flows.
Select the Name of the Mid-Range Speaker 2 PF production flow.
On the Versions FastTab, select Activities.
In the list on the left, select the 00074-Transfer from Warehouse 13 to 51 activity.
On the Successors FastTab, select Add successor. The Create activity relation dialog box opens.
In the Successor group, in the Activity drop-down list, select Activity 000082.
Select the Constraint check box.
In the Constraint value field, enter 1.
In the Units drop-down list, select hr.
In the Cycle time ratio field, enter 2.
Select OK.
Select Save on the Action Pane.
Close the pages.
Exercise - Perform validation and activation
Pierre needs to validate the Mid-Range Speaker 2 PF production flow, Version 2, to confirm that the changes have been correctly implemented.
Go to Production control > Setup > Lean production flow > Production flows. The Production flows form opens.
Select the Name of the Mid-Range Speaker 2 PF production flow. The Production flows form for the selected production flow opens.
On the Versions FastTab, select version 1.
Select Validate. The Validate production flow dialog box opens.
Select OK.
Close the pages.