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Just-In-Time “Eliminate Waste”.

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Presentation on theme: "Just-In-Time “Eliminate Waste”."— Presentation transcript:

1 Just-In-Time “Eliminate Waste”

2 Flexible Resources Multifunctional workers General-purpose machines
Operate more than one machine General-purpose machines Machines that were not highly specialized

3 Cellular Layouts Manufacturing cells Often U-shaped
Work flows through cell in one direction and experiences little waiting

4 Pull System Coordinating production and delivery of materials and parts Traditionally, inventory has been used as a cushion against lapses in coordination and inventory can be huge Pull system observed at US supermarkets Marina Safeway example

5 Pull System Do not order more product than can be used
(or items that can be sold) Reversal of normal ‘push’ system

6 Kanban Production Control System
Japanese word for ‘card’ Associated with fixed-quantity inventory system Two-bin system Kanban

7 Small-Lot Production Requires less space and capital
Produces small amounts at a time Processes can be moved closer together Transport between stations is simplified Quality problems are easier to detect Reveals errors and bottlenecks HP video

8 Lead Time Processing time Move time
Can be reduced by reducing number of items processed and the efficiency or speed of the worker Move time Can be decreased if machines are moved closer together, method of movement simplified, routings are standardized, or need for movement eliminated Con’t

9 Lead Time Waiting Time Setup Time
Can be reduced through better scheduling of materials, workers, machines and sufficient capacity Setup Time Reduction of setup time is important to JIT

10 Quick Setups Separate internal setup from external setup
Internal setup requires the machine to be stopped External setup can be done while machine is running Convert internal setup to external setup Prepare as much as possible in advance (preheating injection mold, standardizing die heights, centering die, etc)

11 Quick Setups Streamline all aspects of setup
Organize workplace properly locating tools near points of use Keep machines and fixtures in good repair Simplify or eliminate adjustments precoding desired settings, using locator pins, etc. Perform setup activities in parallel or eliminate Add a person, standardize components, parts, materials

12 Uniform Production Levels
Smoothing production requirements on the final assembly line Better forecast Mixed production throughout the day in small quantities

13 Quality at the Source For JIT to work, quality has to be high
No extra inventory to buffer against defective units Producing poor-quality items and reworking items or rejecting them is wasteful Workers are responsible for inspection NEVER pass along defective item

14 Quality at the Source Jidoka Andons Undercapacity scheduling
Authority to stop production line if quality problems were encountered Andons Call lights activated by switches Undercapacity scheduling Making time to plan, train, solve problems, maintain work environment

15 Quality at the Source Visual control
Quality improves when problems are made visible and workers have clear expectations of performance Kanbans, andons, process control charts, tool boards, material handling routes clearly marked, demos, instructional photos, performance data

16 Quality at the Source Poka-yoke Kaizen
Foolproof device or mechanism that prevents defects from occurring Kaizen Continuous improvement

17 Total Productive Maintenance
Breakdown maintenance Preventive maintenance Total Productive Maintenance Accurate records on time between breakdowns Frequency of breakdowns Costs of breakdowns Determine a preventive maintenance schedule Employee involvement Zero defects

18 Supplier Networks Working with suppliers to improve responsiveness and quality Trends: Locate near the customer Use small, side-loaded trucks and ship mixed loads Consider establishing small warehouses near to the customer Use standardized containers and make deliveries according to a precise delivery schedule Become a certified supplier and accept payment at regular intervals rather than upon delivery

19 Benefits of JIT Reduced inventory Improved quality Lower costs
Reduced space requirements Shorter lead time Increased productivity

20 Benefits of JIT Greater flexibility Better relations with suppliers
Simplified scheduling and control activities Increased capacity Better use of human resources More product variety

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