Lean Manufacturing and NPIP for Flexible Circuits
March 24, 2016 | Dave Becker, All Flex Flexible Circuits LLCEstimated reading time: 1 minute
Many companies are familiar with lean manufacturing concepts and have successfully used these techniques to improve manufacturing processes. Lean techniques, while most often used in printed circuit fabrication and assembly operations, can also be applied to nonmanufacturing processes. One such process is new part number introduction (NPIP). The main thrust of lean manufacturing is to eliminate or reduce waste. There are typically seven wastes (mudas), as defined by Toyota executive Taiicho Ohno, when he developed Toyota’s Production System (TPS)[1]. (“Muda” is a Japanese word meaning uselessness, idleness or other synonyms of waste.) The seven mudas are:
- Transport
- Inventory
- Motion
- Waiting
- Over-processing
- Over-production
- Defects
The typical part number startup for flexible circuits often can suffer from a number of those wastes. Certain waste items are specific to a part number (customer out of office, conflicts in documentation, iterative design conversations, etc.) or be ingrained as accepted gaps in a supplier’s product launch system. As part of a continuous improvement mentality, wastes should be identified for reduction through a documented and monitored part number introduction process. Some of the more common waste elements are:
Transport: In a new part number introduction process (NPIP), transport is the movement of documentation (electronic or paper) from one department to another requiring successive reviews and sign-offs. Excess transport is a symptom of a departmentalized approach to part number start-up rather than a process flow approach.
Editor's Note: This article originally appeared in the March 2016 issue of The PCB Magazine.
Suggested Items
IDTechEx Report Unveils 3D Electronics Status and Opportunities
04/22/2024 | PRNewswire3D electronics is an emerging manufacturing approach that enables electronics to be integrated within or onto the surface of objects. 3D electronic manufacturing techniques empower new features, including mass customizability, greater integration, and improved sustainability in the electronics industry.
Altus Group Helps BitBox Unlock Productivity and Efficiency Gains with New Reflow Oven
04/22/2024 | Altus GroupAltus Group, a leading provider of capital equipment, has recently assisted BitBox, a UK-based electronics design, engineering and manufacturing company in upgrading its operations with the implementation of a new reflow oven from Heller Industries.
Growth Potential: Electronics Manufacturing Driving Massive Surge in Manufacturing Investment
04/22/2024 | Shawn DuBravac, IPCIn the early months of the pandemic, investment in manufacturing infrastructure, such as plants and production facilities, declined sharply. Real investment dropped over 11%, before finally recovering to pre-pandemic levels in the first half of 2022. Over the past two years, however, several factors have combined to drive manufacturing investment to record levels.
I-Connect007 Editor’s Choice: Five Must-Reads for the Week
04/19/2024 | Marcy LaRont, PCB007 MagazineFor my must-read picks of the week, I’m highlighting Parker Capers, a young professional seeking employment, solid counsel from Dan Beaulieu on what your post-show plan should look like, more information and insight on “chiplets” and the need for secure data transfer standards from columnist Preeya Kuray, as well as Matt Stevenson’s design for reality wisdom. It’s a reminder to download one of our newest books (there are several) you don't want to miss if you are an assembler.
Absolute EMS Champions Collaboration Between Humans and Robots in Modern Manufacturing
04/19/2024 | Absolute EMS, Inc.Absolute EMS, Inc., an award-winning EMS provider of turnkey contract manufacturing services, offers a perfect factory environment that seamlessly blends robotic automation with human expertise.