Mixed Model Line Design

Before diving into the content, take this short introduction to learn how to use this platform and what to expect from this online course.

This is an introduction to the Mixed Model Line Design Roadmap, the step-by-step process you will be following throughout your line design project.

Lesson 3 takes you through some of the most important line design fundamentals. First you’ll learn how to read the current state of your production line. Then you will receive a short introduction to Value Stream Mapping and some of the other essential line design tools.

The basic fundamentals are in place, but how do you actually get started with a line design? We’ll discover that, along with the benefits of mixing products in this lesson. Finally, you will discover how Forecast Daily Volume impacts your resource calculations.

We’ll begin this lesson by defining a process then work towards building one of the most important resources in all of mixed model line design: a Process Flow Diagram.

How do you use a Mixed Model Process Flow Matrix to help build your Mixed Model Process Flow Diagram?

Understanding and calculating Takt time is extremely important when designing a mixed model line. In this lesson, we’ll define Takt and then build on that definition to insure that you are completely confident about what Takt is and, even more importantly, what it is NOT. Hint: It is not used for products.

Learn the factors that affect Takt time, and how to calculate them.

Standard work is a foundational element of Lean. In this lesson, we will discuss the benefits of Standard work, how to use Standard Work, and why it is important to use graphics in your Standard Work definitions.

Understand how to use the Resource Calculation Formula, and learn how to interpret and apply the results of your Resource Calculations.

In this lesson, you will learn how to calculate the necessary number of workstations on your line and how to determine the distribution of work between those workstations.

In-Process Kanbans (IPKs) are a necessary component of many mixed model production lines. In this lesson we will introduce the benefits and application of IPKs, as well as the best methods for calculating the optimum number of IPKs between your workstations.

Learn about the six line balancing tools, how to use them, when to use them, and the incredible benefits that come with a well balanced line.

Every line designer has to consider how machine processes will impact his or her line. In this lesson, you will learn about the different types of machines, their strengths and weaknesses, and how to integrate machines with IPKs and the balancing tools.

Every mixed model production line has to deal with changeovers, but you don’t have to allow those changeovers ruin your design. This lesson is all about strategies to minimize, as much as possible, the negative impact of changeovers on your line design.

Before jumping straight into CAD, it is important to first create a conceptual design. In this lesson you will learn why conceptual designs are useful, how to create them, and which inputs go into a conceptual line design.

In many cases, Simulation Modeling is not an option. Used correctly, it can save millions of dollars and days of work. This chapter focuses on the creation of Simulation Models. When is Simulation Modeling necessary? What data goes into a successful model? How do you get that data? And, when the model is completed, how do you analyze those results?

Once you CAD drawing is complete, how do you take that drawing and turn it into a live production line? That is the focus of this lesson. And, as a bonus, we’ll teach you about the single most underutilized strategy in the line design toolkit: flexing.

Your line design is complete. Your line is live. Now what? In this final lesson, we will discuss how to take the next steps beyond Mixed Model Line Design.