JIT-17p

JIT
14
Kanban Production Control Systems (Cont.)
• Kanban…Cards
• Production Card---”P” Card:
2-card system
– Part #, Quantity to be produced, Supply work center #, etc.
JIT 12
Push System
• Production authorized in anticipation of needs downstream…(cue is a work order from the planning system) • Orders launched to meet due dates. • Keep machines & people busy.
JIT
16
Setup Reduction (Cont.)
• Setup activities:
– External: Operations performed while the machine is running. – Internal: Operations performed after the machine is stopped.
• Setup reduction is the process of reducing the time required to convert from production of the last good piece of unit A to the first good piece of unit B. • use methods engineering/common sense. • Ideal lot size = 1.
JIT
1
Just-In-Time (JIT) (Cont.)
• Management philosophy…Nothing produce until needed. • Encompasses the successful execution of all production activities required from design to delivery of products. • Common sense based/simple techniques
JIT
2
Just-In-Time (JIT) (Cont.)
• Minimize waste of time, energy, material & errors • Minimize waste…in both factories: Manufacturing product & “Hidden” • Attack/eliminate waste • Value added to the final product philosophy … from customer’s point of view
– Reducing the amount of inventory in the system – “One less at a time”…(reducing the lot size)
• expose eliminate constraints
JIT 11
Pull System
• Produce only when material is needed downstream…(cue from the user not the planning source) • Pull materialБайду номын сангаас sequentially through the factory. • Orders placed at end item level. • Idle material is waste. • Need discipline…(Good practices reinforced through training)
JIT
9
JIT Manufacturing (Cont.)
• • • • • No Inventories, No queues Minimum schedule variation Uniform plant loading Uninterrupted flow of materials Flow paced by market demands Flexibility, Visual Control (make problems visible to everyone), Reliability (of materials, people & equipment)
Just-In-Time (JIT)
JIT: an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials, finished goods & work in process.
• Simple, paperless procedures • Signals/visual systems
– Posted schedules
• Containers
– Standard size, small
• Factors: Material Handling consideration proximity of work centers
JIT
8
JIT Manufacturing
• JIT Manufacturing: Executing linear production: Production of necessary units in the necessary time with the objective of ± 0 Variance W.R.T. the schedule.
• Setup…responsibility of the operator.
JIT
17
JIT 3
Just-In-Time (JIT) (Cont.)
• Expose problems • Continuous improvement/change • Enforced problem solving approach
JIT
4
Goals
• Zero defects…reducing defects • Zero inventory…Stockless production • Zero setup time… SMED---Single Minute Exchange of Dies • Zero handling • Zero break down
NOTE: Planning is necessary under JIT to ensure the right amount of productive resources are scheduled/available to satisfy MPS/FAS
JIT 13
Kanban Production Control Systems
• Conveyance (Move) Card---”C” Card:
– Part #, Container Capacity, Source, Destination, etc.
1-card system: Move card and an empty space
JIT
15
Setup Reduction
• Focused Factory…specialized • Group Technology…Eliminate movement & queue time between operations • Jidoka…Quality at the source stop line if necessary
JIT 10
JIT Manufacturing (Cont.)
• Inventory hides problems such as poor quality, break downs, late deliveries, workers absence & tardiness, etc. Tightening the production system:
– Total quality: an approach that encompasses all phases of a manufacturing organization.
JIT
7
Elements addressing Elimination of Waste (Cont.)
Quality…Meeting a specific set of customer expectations • Fitness for use, reliability, consistency, etc. • Customer…external & internal
JIT 5
Goals (Cont.)
• Zero lead time • Zero Transactions…reduced paperwork • Zero disturbances…routine execution of schedules
JIT
6
Elements addressing Elimination of Waste