Презентация на тему Just in time & lean manufacturing. Chapter 15

Business Philosophy
Production system: manufacturing & movement of materials and

goods occur just when they are needed, usually in small batches
JIT operates with very little “fat” (waste)
Defines waste in terms of customer value
JIT Goals
Eliminate disruptions
Make system flexible by reduce setup and lead times
Eliminate waste, especially excess inventory

finished in WC 10 wait to move out of

the WC

Arrive at WC 20 –wait to be worked on

Move

After finished in WC 20 wait to move out of WC

Large Batch sizes impact Wait times!

sell now
Waiting time – for the next process
Unnecessary handling

& transportation
Processing waste
Inefficient work methods
Product defects – producing bad
quality items

maintenance to reduce unexpected breakdowns
Cross-train workers to help clear

bottlenecks – workers skilled in many different work processes
Reserve capacity for important customers Ex. Operate at 90-95% capacity – is this a good strategy?

design

improvements –preventive actions
Reduced inventory

frequent machine setups

Workers are trained to do their own

setups

Do as much of the set-up external from the manufacturing process

Group Technology may be used to reduce cost and setup time (group similarly-made products)

Setup Time Reductions

process variability
Poka Yoke to mistake-proof

Autonomation:
Automatic detection of defects

during production Ex. Laser beams to check fill amounts of bottles

Quality Improvement

work cell teams

amount of production Example – always produce batches of

5 pieces
Use Pull Systems and Kanban (card signal system) – automate production control
Close supplier relationships with key suppliers
Visual systems – easy to see problems. Example – green light when machine running, red light when broken down
Preventive maintenance – to reduce unexpected machine breakdowns

work where a workstation pulls output from the preceding

station as needed. (e.g. Kanban)
Push system:
System for moving work where output is pushed to the next station as it is completed
Kanban:
Card or other device that communicates demand for work or materials to the preceding station
Kanban: Japanese word meaning “signal” or “visible record”
Paperless production control system
Authority to pull, or produce comes from a downstream process.

PUSH system we tend to produce more to offset

waste (including quality)

– Stores to replenish
Empty means – bring another!

good operating condition and replacing parts that have a

tendency to fail before they actually do fail

Housekeeping
Maintaining a workplace that is clean and free of unnecessary materials (5S program)
Sort
Straighten
Shine
Standardize
Sustain