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Just-In-Time Systems
JIT/Lean Production
Just-in-time: Repetitive production system in
which processing and movement of materials and goods occur just as they are needed, usually in small batches
JIT is characteristic of lean production systems JIT operates with very little fat
JIT Goals
Eliminate disruptions Make system flexible by reduce setup and lead times Eliminate waste, especially excess inventory
Sources of Waste
Overproduction Waiting time
Unnecessary transportation
Processing waste
Personnel/organizational elements
Manufacturing planning and control
Product Design
Standard parts Modular design Highly capable production systems
Process Design
Small lot sizes Setup time reduction
Manufacturing cells
Limited work in process
Quality improvement
Production flexibility Little inventory storage
Production Flexibility
Reduce downtime by reducing changeover time
Personnel/Organizational Elements
Workers as assets Cross-trained workers Continuous improvement
Cost accounting
Leadership/project management
Pull/Push Systems
Pull system: System for moving 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
Buyer
Supplier Supplier Supplier Supplier Supplier
Supplier
Suppiler
Figure 16-3a
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Figure 16-3b
Supporting Goals
Reduce setup and lead times Eliminate waste Eliminate disruptions Make the system flexible Minimize inventories
Product Design
Process Design
Personnel Elements
Manufacturing Planning
Building Blocks
Obstacles to Conversion
Management may not be committed Workers/management may not be cooperative Suppliers may resist
JIT in Service
The basic goal of the demand flow technology in the service organization is to provide optimum response to the customer with the highest quality service and lowest possible cost.
Eliminate disruptions Make system flexible Reduce setup and lead times Eliminate waste Minimize WIP Simplify the process
JIT Purchasing
New challenges
Meeting manufacturing requirements Changing from traditional thinking and practices frequent on-time delivery of small quantities Long term relationships with suppliers as partners
JIT II
JIT II: the practice of allowing vendors to manage some aspects of buying their products or services for the buyer
Sources of Waste
Waste from overproduction Waste of waiting time Transportation waste
Inventory waste
Processing waste
Waste of motion
Waste from product defects
Table 16-5
Elements of JIT
Smooth flow of work (the ultimate goal) Elimination of waste Continuous improvement Eliminating anything that does not add value Simple systems that are easy to manage Use of product layouts to minimize moving materials and parts Quality at the source
Table 16-5
Table 16-5
Kanban
(the visual system)
What is Kanban?
N = Total number of containers D = Planned usage rate of using WC T = Average wait time + production time X = Efficiency number (by policy) C = Capacity per container
DT 1 X N C
300.121 .2 N 1.728 2 25
Number of containers Planned usage rate WC Cycle time efficicnet factor Parts per container
N D T X C
N=