-Agile _QR_Manufacturing.pptx

8/18/2019 -Agile _QR_Manufacturing.pptx

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Quick Responseor Agile

Manufacturing


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Today's theater of competition

for manufacturing firms isspeed — not only speed ofdelivery, but of concept, design

and production. e! doorsopen for those !ho can getproducts to market before the

competition, and successhinges on the ability to respond"uickly.


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Quick Response Manufacturing

#QRM$ is a company!ide strategy

to cut lead times in all phases of

manufacturing and office

operations. %t can bring yourproducts to market more "uickly

and secure your business

prospects by helping youcompete in a rapidly changing

manufacturing arena.


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It will increase

profitability by reducing

non–value–added time,

cutting inventory andincreasing return on

investment.


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The benefits of QRM are &

• a$ Reduce lead times

throughout your

organiation• b$ (ecrease your

manufacturing costs

c$ %ncrease your market

share


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d$ )ill customer ordersfaster e$ *oost product "ualityf$ %ntroduce ne! products

rapidlyg$ +liminate !aste andinefficiency

h$ ecure yourmanufacturing future


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The phrases "+fficient

-onsumer Response" in

the food industry and "Quick

Response" in the clothingindustry have been used to

describe similar features of

Agile Manufacturing


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Conventionally, agile means fast

moving. Agility means an etensionto fleibility. !leibility is the ability torespond rapidly and adapt to

changes. It includes dimensions ofvolume, product, process mi,delivery and operations. ut agilitygoes beyond fleibility and mergesthe components of fleibility, #uality,cost and reliability.


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Agility implies being

fleible with high

#uality, low cost ,superior service and

greater reliability


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Agile or $uic% response

Manufacturing means productionof highly customi&ed productsand #uic% responses to

customer demand withoutassociated higher costs, throughefficient and effective use offleible and programmablemachinery and reconfigurableproduction facilities.


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Traditional 'ractice Current 'ractice

(td. di&ed or uniform Customi&ed or

'roducts highly variable

products

)onger Mar%et )ife (horter Mar%et )ife

'roduced to forecast 'roduced to order


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)ow information *igh information

Content Content

'riced by 'riced by customer

Manufacturing unit perceived value

Cost + margin


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(pecific mar%et Multiple mar%et

iche iche

(elf Contained open for

upgrades -

information -

(ervices


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The core concepts of agility


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Agile manufacturing is a

term applied to anorgani&ation that has created

the processes, tools, and

training to enable it to respond

#uic%ly to customer needs and

mar%et changes while stillcontrolling costs and #uality.


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An enabling factor in becoming an

agile manufacturer has been thedevelopment of manufacturingsupport technology that allows themar%eters, the designers and the

production personnel to share acommon database of parts andproducts, to share data on productioncapacities and problems particularly where small initialproblems may have largerdownstream effects.

http://en.wikipedia.org/wiki/Downstream_(manufacturing)http://en.wikipedia.org/wiki/Downstream_(manufacturing)


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It is a general proposition of

manufacturing that the cost of

correcting #uality issues

increases as the problemmoves downstream, so that it

is cheaper to correct #uality

problems at the earliestpossible point in the process.


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Agile manufacturing is seen as the

net step after )/A in theevolution of production methodical.

The %ey difference between the two

is li%e between a thin and anathletic person, agile being the

latter. 0ne can be neither, one or

both. In manufacturing theory beingboth is often referred to as leagile.


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According to Martin Christopher,

when companies have to decidewhat to be, they have to loo% at the

Customer 0rder Cycle 1the time

the customers are willing to wait2and the lead time for getting

supplies. If the supplier has a short

lead time, lean production is

possible. If the customer order

cycle is short, agile production is

beneficiary.


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The order cycle is the total time

taken from customer initiation of the

order through receipt of the product

or service by the customer. Thus, if

a sales person obtain an order from

a customer holds it for fe! daysbefore entering the order then that

those fe! days get added to the

order cycle time, even though thosedays !ere invisible to the

distribution center.

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+lements of the ordercycle include placing theorder, order entry #if

separate from placement$,order placing pickingfor shipment, transit time,

and the actual deliveryprocess.

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-ustomers tend to be more

concerned !ith the consistency oftotal lead times than !ith absolutelead time. o it is important tomonitor actual performance in thisregard take corrective action!henever needed. /o!ever, !iththe increased emphasis on time

based competition, reducing totalcycle time has received greaterattention.

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0ust %n TimeManufacturing


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0ust in time is a 1pull2 system

of production, so actualorders provide a signal for!hen a product should be

manufactured. (emand&pullenables a firm to produceonly !hat is re"uired, in the

correct "uantity and at thecorrect time.


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This means that stoc% levels of

raw materials, components,wor% in progress and finished

goods can be %ept to a

minimum. This re#uires a

carefully planned scheduling

and flow of resources throughthe production process.


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Modern manufacturing firms usesophisticated production

scheduling software to planproduction for each period oftime, which includes ordering the

correct stoc%. Information isechanged with suppliers andcustomers through +(% 1+lectronic (ata %nterchange2 tohelp ensure that every detail iscorrect.


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(upplies are delivered right tothe production line only whenthey are needed. !or eample,a car manufacturing plant mightreceive eactly the right number

and type of tyres for one day8sproduction, and the supplierwould be epected to deliver

them to the correct loading bayon the production line within avery narrow time slot.


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• Advantages of 0%T in 3roduction

• )ower stoc% holding means a reduction

in storage space which saves rent andinsurance costs

• As stoc% is only obtained when it is

needed, less wor%ing capital is tied up instoc%

• There is less li%elihood of stoc%

perishing, becoming obsolete or out ofdate


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•

Avoids the build4up of unsold finishedproduct that can occur with sudden

changes in demand

•

)ess time is spent on chec%ing and re4wor%ing the product of others as the

emphasis is on getting the wor% right

first time


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• (isadvantages of 0%T in 3roduction

• There is little room for mista%es asminimal stoc% is %ept for re4wor%ingfaulty product

• 'roduction is very reliant on suppliers

and if stoc% is not delivered on time,the whole production schedule can bedelayed

• There is no spare finished productavailable to meet unepected orders,because all products are made to meet

-Agile _QR_Manufacturing.pptx

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