Pull Manufacturing and Just In Time

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Presentation transcript:

Pull Manufacturing and Just In Time Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

© 2007 Superfactory™. All Rights Reserved. Contents Introduction Background and History Components and Implementation Knowledge Check © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. Introduction Just In Time (JIT) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and cycle time. The process is driven by a series of signals, or Kanban, that tell production processes to make the next part. When implemented correctly, JIT can lead to dramatic improvements in a manufacturing organization's return on investment, quality, and efficiency. © 2007 Superfactory™. All Rights Reserved.

Components and Implementation Pull vs. Push Scheduling The Problem of Inventory Just In Time Principles Benefits and Limitations Implementing JIT Kanban Pull Systems Quality One Piece Flow Continuous Flow Takt Time JIT and Suppliers © 2007 Superfactory™. All Rights Reserved.

Push Vs. Pull Scheduling Push Scheduling traditional approach “move the job on when finished” problems - creates excessive inventory Pull scheduling coordinated production driven by demand (pulled through system) extensive use of visual triggers (production/withdrawal kanbans) © 2007 Superfactory™. All Rights Reserved.

Inventory Hides Problems Scrap Work in process inventory level (hides problems) Unreliable Vendors Capacity Imbalances © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. The Philosophy of JIT JIT means getting the right quantity of goods at the right place and the right time Often termed “Lean Systems” All waste must be eliminated- non value items Broad view that entire organization must focus on serving customers JIT is built on simplicity- the simpler the better Focuses on improving every operation- Kaizen Install simple visible control systems Flexibility to produce different models/features © 2007 Superfactory™. All Rights Reserved.

Elements of JIT Manufacturing JIT Manufacturing is a philosophy of value-added manufacturing Achieved by Inventory reduction - exposes problems Kanbans & pull production systems Small lots & quick setups Uniform plant loading Flexible resources Efficient facility layouts © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. JIT Tactics Single Minute Exchange of Dies (SMED) Statistical Process Control Use of standard containers Doable stable schedules with adequate visibility TAKT-Time 5-S Program Kaizen Event Visual control Flexible workers Tools at the point of need Product redesign Group Technology Total Productive Maintenance © 2007 Superfactory™. All Rights Reserved.

© 2007 Superfactory™. All Rights Reserved. JIT and Suppliers Few Nearby (if possible) Repeat business/Longer Term Agreements Analysis to enable desirable suppliers to become or stay price competitive JIT Logistics: Frequent Deliveries/Smaller Quantities Exact Quantities Consumption initiates deliveries Deliveries directly to the point of use Perfect Parts Concurrent engineering design practices © 2007 Superfactory™. All Rights Reserved.