University of Missouri, St. Louis IRL @ UMSL Dissertations UMSL Graduate Works 7-6-2014 Takt Time Grouping: A Method to Implement Kanban-Flow Manufacturing in an Unbalanced Process with Moving Constraints Mitchell Alan Millstein University of Missouri-St. Louis, [email protected] Follow this and additional works at: https://irl.umsl.edu/dissertation Part of the Business Commons Recommended Citation Millstein, Mitchell Alan, "Takt Time Grouping: A Method to Implement Kanban-Flow Manufacturing in an Unbalanced Process with Moving Constraints" (2014). Dissertations. 242. https://irl.umsl.edu/dissertation/242 This Dissertation is brought to you for free and open access by the UMSL Graduate Works at IRL @ UMSL. It has been accepted for inclusion in Dissertations by an authorized administrator of IRL @ UMSL. For more information, please contact [email protected]. Takt Time Grouping A Method to Implement Kanban-Flow Manufacturing in an Unbalanced Process with Moving Constraints & Comparison to One Piece Flow and Drum Buffer Rope: Which is Better, When and Why Mitchell A. Millstein M.B.A, Washington University – St. Louis, MO, 1996 B.S., Engineering, Rutgers University – New Brunswick, NJ, 1988 A Thesis Submitted to The Graduate School at the University of Missouri – St. Louis in partial fulfillment of the requirements for the degree Ph.D. in Business Administration with an emphasis in Logistics and Supply Chain Management Advisory Committee Joseph P. Martinich, Ph.D. Chairperson Robert M. Nauss, Ph.D. L. Douglas Smith, Ph.D. Donald C. Sweeney II, Ph.D. Revision: July 2, 2014 Copyright, Mitchell A. Millstein, 2014 1 Contents Abstract ......................................................................................................................................................... 7 Section 1: Introduction ................................................................................................................................. 8 Section 1.1: Flow Cell Methods ................................................................................................................. 8 Section 1.2: Research Motivation ............................................................................................................. 9 Section 1.3: Takt Time Grouping Concept .............................................................................................. 12 Section 1.4: Manuscript Sections ............................................................................................................ 13 Section 2: Literature Review ....................................................................................................................... 15 Section 2.1: Cellular Manufacturing ....................................................................................................... 15 Section 2.2: Kanban and One-Piece Flow ............................................................................................... 16 Section 2.3: Theory of Constraints and DBR ........................................................................................... 18 Section 2.4: Combining DBR and One-Piece Flow .................................................................................. 19 Section 2.5: Comparing DBR and One-Piece Flow .................................................................................. 20 Section 2.6: Transfer-Batch Sizing ........................................................................................................... 22 Section 2.7: Gaps in the Research ........................................................................................................... 22 Section 3: The Takt Time Grouping Method ............................................................................................... 24 Figure 1: Logic Flow for Determining Tempo time (T) ........................................................................ 28 Table 1: Data for Choosing the Takt Time Grouping Tempo time ...................................................... 29 Section 4: Key Research Questions ............................................................................................................. 30 Section 5: Details of the Research Methodology ........................................................................................ 36 Section 5.1: Full Factorial ANOVA Experimental Design ......................................................................... 36 Table 2: Full Factorial Experimental Design ........................................................................................ 37 Figure 2: Piston-Disc in a Takt Time Group Kanban Tray .................................................................... 39 Table 3: Piston Disc Operation Cycle Time Data in Seconds ............................................................... 40 Figure 3: Slide-Valve ............................................................................................................................ 41 Table 4: Slide-Valve Operation Cycle Time Data in Seconds ............................................................... 42 Figure 4: Small Solenoid Valve ............................................................................................................ 43 Table 5: Small Solenoid Valve Operation Cycle Time Data in Seconds ............................................... 44 Section 5.2: Labor Resource Experimental Design ................................................................................. 45 Section 5.3: Makespan Experimental Design .......................................................................................... 47 Section 6: Discrete Event Simulation Model ............................................................................................... 49 Revision: July 2, 2014 Copyright, Mitchell A. Millstein, 2014 2 Table 6: Transfer-Batch Sizes .............................................................................................................. 55 Section 7: Performance of One-Piece Flow, DBR, DynDBR and TTG Under Varying Conditions – Light Machining Flow Cell Process ....................................................................................................................... 56 Section 7.1: Overall Results for the Light Machining Process ................................................................. 57 Table 7: Results for Light Machining Flow Cell Process ...................................................................... 58 Section 7.2: Effect of Move-Time on Throughput Rate – Light Machining Process ............................... 59 Table 8: Average Throughput Rate Results for Move-Time Factor Settings – Light Machining Process ............................................................................................................................................................ 59 Section 7.3: Effect of Operation Cycle Time Variation on Throughput Rate – Light Machining Process 62 Table 9: Average Throughput Rate Results for Operation Cycle Time Variation Factor Settings – Light Machining Process .............................................................................................................................. 62 Figure 5: One-Piece Flow WIP by Hour – Light Machining Process .................................................... 64 Figure 6: WIP in Each Operation – Light Machining Process .............................................................. 67 Section 7.4: Effect of Set-Up Time on Throughput Rate – Light Machining Process .............................. 68 Table 10: Average Throughput Rate Results for Set-Up Factor Settings – Light Machining Process . 68 Figure 7: Zero WIP % of Time in Each Operation – Light Machining Process ..................................... 70 Figure 8: DBR WIP by Hour – Light Machining Process ....................................................................... 72 Table 11: WIP by Operation: Average and at Shutdown – Light Machining Process ......................... 76 Section 7.5: Factor Interaction Effects on Throughput Rate – Light Machining Process........................ 77 Figure 9: Factor Interaction Effects for One-Piece Flow, DBR, DynDBR, TTG – Light Machining Process ................................................................................................................................................ 78 Table 12: p-values of Interaction Effects – Light Machining Process.................................................. 79 Table 13: One-Piece Flow Interaction Effect Table – Light Machining Process .................................. 79 Table 14: DBR Interaction Effect Table – Light Machining Process .................................................... 80 Section 7.6: Comparison of the Four Methods – Light Machining Process ............................................ 80 Table 15: Throughput Rate Comparison – Light Machining Process .................................................. 83 Section 7.7: TTG’s Robustness – Light Machining Process ..................................................................... 88 Section 8: Performance of One-Piece Flow, DBR, DynDBR and TTG Under Varying Conditions – Heavy Machining Flow Cell Process ....................................................................................................................... 91 Section 8.1: Overall Results for the Heavy Machining Process ............................................................... 91 Table 16: Results for Heavy Machining Flow Cell Process .................................................................