Agile - Manufacturing (1) Power Point - ppt222

Introduction
• Manufacturing industry is on the

verge of a major paradigm shift.
This shift will take us away from
mass production, way beyond
lean manufacturing, into a world
of Agile Manufacturing (5)
What is Agile
Manufacturing?
Agile manufacturing is a method
for manufacturing which
combine our organization,
people and technology into an
integrated and coordinated
whole. (5)
Why do we need to be
agile
Global Competition is intensifying.
• Mass markets are fragmenting into
niche markets.
• Cooperation among companies is
becoming necessary, including
companies who are in direct
competition with each other.
Why do we need to be
agile cont:
• Customers are expecting:
1. Low volume products
2. High quality products
3. Custom products
• Very short product life-cycles,
development time, and production
lead times are required.
• Customers want to be treated and
individuals (4)
Keys to agility and
flexibility
• To determine customer needs quickly and

continuously reposition the company
against its competitors.
• To design things quickly based on those
individual needs.
• To put them into full scale, quality,
production quickly.
• To respond to changing volumes and mix
quickly.
• To respond to a crisis quickly. ((1))
Agile manufacturing in
our company
• Customer-integrated process for designing,
Manufacturing , marketing , and supporting
all products and services.
• Decision making at functionally knowledge
points not in centralized management
“silos”
• Stable unit costs no matter what the
volume
• Flexible Manufacturing ability to increase production.
Agile manufacturing in
our company cont.
• Easy access to integrated data whether it
is customer--driven,, supplier--driven,, or
product and process--driven
• Modular production facilities that can be
organized into ever changing
manufacturing nodes..
• Data that is rapidly changed into
information that is used to expand
knowledge.
• Mass customized product verses mass
produced product.. ((1))
Four core concepts
• Enriching the customer
1.. Replace large centralized with
distributed clusters off mini-assembly
plants located near customers.
• Cooperating to enhance
competition.
1.. Internal—cross-functional teams,
empowerment.
2.. External—managing the supply chain.
Nuts and Bolts
 • Enriching the customer
 1.. Replace large centralized with
 distributed clusters off minim--assembly
 plants located near customers..
 • Cooperating to enhance
 competition.
 1.. Internal cross-functional teams,
 empowerment.
 2.. External managing the supply chain.
 Nuts and Bolts
 • Organizing to manage change and
 uncertainty
 1.. Rapid reconfiguration off plant and
 facilities.
 2.. Rapid decision making-shallow
 empowered.
 • Leveraging people and information.
Interdisciplinary Design
Interdisciplinary design will form
the basis of designing Agile
Manufacturing systems in the new
knowledge intensive era.
Interdisciplinary design is one of the
most important challenges to that
managers and systems designers and
integrators will face in the years
ahead, it leads us to new approaches
and new ways of working and of
thinking. (5)
Interdisciplinary Design
To successfully adopt an
interdisciplinary design method, we
need to:
• Challenge our accepted design
strategies and develop new and
better approaches.
• Question our established and
cherished beliefs and theories, and
develop new ones to replace those
that know longer have any validity.
(5)
Real world example:
• The Industry: Japanese car
makers
• The goal: To produce the three
day car, (three days from
customer order for a
customized car to dealer
delivery)
Real world ex. Cont.
The Challenges::
• The challenges::
1.. Break dependency on scale and
economies off scale ((reducing setup
costs in key))..
2.. Produce vehicles in low volumes at a
reasonable cost..
3.. Guarantee the three day car..
4.. Replace large centralized with
distributed clusters off minim--assembly
plants located near customers..
 5.. Be able to reconfigure components in
many different ways.
Real world ex. Cont.
The Challenges::
1. Make work stimulating.
2. Turn the customer into a “prosumer,” an ugly
neologism that means proactive something; the
idea is that the customer will take an active
role in the product design by, for example,
configuring options at a computer in a dealer
showroom.
3. Streamline ordering systems and establish
close relationships with suppliers.
4. Manage the massive volumes of data generated
by the production system so as to be able to
analyze that data quickly and agilely (3)
Exercise
War has broken out somewhere in
the world, and the US becomes
involved. Suddenly, all branches of
our armed forces need more
conventional munitions-and they
need them immediately. How can
suppliers meet this kind of
unpredictable demand? (2)
Summery
Agile Manufacturing enterprises will be
capable of rapidly responding to changes in
customer demand. They will be able to take
advantage of the windows of opportunities that
appear in the market place. With Agile
Manufacturing we will be able to develop new
ways of interacting with our customers and
suppliers. Our customers will not only be able
to gain access to our products and services,
but will also be able to easily assess and
exploit our competencies, so enabling them to
use these competencies to achieve the things
that they are seeking. (5)
Bibliography
• Abair, Bob. Agile Manufacturing: Not Just Another
Buzzword.
http://www.partnersforexcellence.com/95art3.htm
• Agile Manufacturing: Gearing to meet demand.
Linkages http://www.llnl.gov/str/Burleson.html
• “Agile Manufacturing” linkages
http://www.peterkeen.com/engbp003.htm
• D&ME. Pacific Northwest National Laboratory.
Linkages
http://www.technet.pnl.gov/dme/agile/index.stm
• Kidd, T. Paul. Agile Manufacturing: Forging New
Frontiers.
http://www.cheshirehenvury.com/publications/ammaterial..

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Introduction

• Manufacturing industry is on the

• To determine customer needs quickly and

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