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Lean Operations
• Can be define as moving towards the elimination of all
waste in order to develop an operation that is faster, more
dependable, produces higher quality products & services
and operates at low cost.
2.2 JIT definitions
Fig.3
2.3.2 JIT approach
Fig.3:
The many problems of operation are shown as rocks
in the river bed which cannot be seen because of the
depth of water (excess inventory), as in the traditional
approach. Yet, even through the rocks cannot be seen,
they slow the progress of the water (inventory) flow
and cause turbulence.
If the level of inventory (water) is reduced, the
problem (rocks) are exposed and can be resolved. The
key message is that high inventories are costly and
hide the problems, which are impeding product flow,
which in turn requires high inventory levels
2.4 JIT and Capacity Utilization
• The three key issues that define Lean philosophy that underpins the
techniques of
• JIT are: (1) Elimination of waste, (2) Involvement of everybody
and (3) the drive for continuous improvement.
• As shown below, the JIT techniques (i.e. managing operations &
planning and control) support and allow the key principles of Lean
to be achieved, particularly waste reduction.
2.6 The lean philosophy of operation
Eliminate Waste
• Waste can be defined as any activities which does not add
value.
• Toyota identified 7 types of generic waste that can be found in
any manufacturing operations:
(1) Over-production
Is considered the greatest source of waste
(2) Waiting time
Machine efficiency and labour efficiency are two main measures of
waiting time.
(3) Transport
Moving materials around the plant does not add any value.
Layout changes which bring processes closer together, improvements
in transport methods and workplace organization can all reduce waste.
2.6 The lean philosophy of operation
(4) Process
Some operations may only exist because of poor component design, or
poor maintenance, and so could be eliminated.
(5) Inventory
Should be kept to minimum or complete elimination.
Tackling the root cause of inventory can eliminate inventory
(6) Motion
An operator may look busy but sometime no value is being added by
the work.
Simplification of work is a rich source of reduction in the waste of
motion
(7) Defective goods
Cost money and therefore the cause of poor quality must be tackled.
2.6 The lean philosophy of operation
Continuous Improvement
• Lean philosophy believes that the way to reach perfection is
through continuous improvement.
Question-1:
Question-2:
Question-3:
JIT Techniques
2.7 JIT Techniques
Continuous Improvement