Date post: | 30-May-2018 |
Category: |
Documents |
Upload: | dilfaraz-kalawat |
View: | 222 times |
Download: | 0 times |
of 27
8/14/2019 JIT & Kaizen-Fundas
1/27
Just-In-TimeSystems
8/14/2019 JIT & Kaizen-Fundas
2/27
What is JIT ? Producing only what is
needed, when it is needed A Practical philosophy
An integrated management
system.
JITs mandate: Eliminate allwastes & Variations.
8/14/2019 JIT & Kaizen-Fundas
3/27
Basic Elements of JIT1.Flexible resources
2.Cellular layouts
3.Pull production system
4.Kanban Replenishment control5.Small-lot production
6.Quick setups
7.Aligned production8.Quality at the source
9.Total Productive Maintenance
10. Supply Chain Management- networking
8/14/2019 JIT & Kaizen-Fundas
4/27
Examples of Waste Watching a machine run Waiting for parts
Non- Standard batches of parts
Overproduction
Moving parts over long distances
Storing inventory
Searching for tools, consumables, parts,gauges
Machine breakdown
Re- work / pair / make / do
8/14/2019 JIT & Kaizen-Fundas
5/27
Flexible Resources Multi functional / skilled
workers
General purpose machines
Multi use Tool / Fixtures / Jigs
8/14/2019 JIT & Kaizen-Fundas
6/27
Standard Operating
Routine
8/14/2019 JIT & Kaizen-Fundas
7/27
Cellular Layouts Group dissimilar machines in
manufacturing cell to producefamily of parts
Work flows in one direction
through cell Cycle time adjusted by
changing worker paths
8/14/2019 JIT & Kaizen-Fundas
8/27
Manufacturing Cell
With Worker RoutesEnter
Worker 1
Worker 2Worker
3
Exit
Key:Product routeWorker route
Machines
8/14/2019 JIT & Kaizen-Fundas
9/27
Kanban
ReplenishmentControl System Kanban indicates standard quantity of
production / supply for replenishment
Derived from two-bin inventory system
Kanban maintains discipline of pullproduction
Production Kanban authorizes production
Withdrawal Kanban authorizes movement ofgoods
8/14/2019 JIT & Kaizen-Fundas
10/27
A Sample Kanban
Machining
M-2
Assembly
A-4
Part no.: 7412
Description: Slip rings
From : To:
Box capacity 25
Box Type A
Issue No. 3/5
8/14/2019 JIT & Kaizen-Fundas
11/27
Kanban Squares
X X X
XX
X
Flow of workFlow of information
8/14/2019 JIT & Kaizen-Fundas
12/27
Types Of Kanbans Kanban Square
marked area designed to hold items
Signal Kanban triangular Kanban used to signal production at
the previous workstation
Material Kanban
used to order material in advance of a process
Supplier Kanbans
rotate between the factory and suppliers
8/14/2019 JIT & Kaizen-Fundas
13/27
Determining Number
Of Kanbans
where
N = number of Kanbans d = demand over defined time period
L = lead time to produce parts
S = safety stock
C = container size
No. of kanbans =mand during lead time + safety stock
containersize
average de
N
dL S
C=
+
8/14/2019 JIT & Kaizen-Fundas
14/27
Small-Lot Production Requires less space & capital
investment Moves processes closer together
Makes quality problems easier
to detect Makes processes more driven by
each other
8/14/2019 JIT & Kaizen-Fundas
15/27
Inventory Hides
Problems
PoorQuality
Unreliable
Supplier
Machine
BreakdownInefficient
Layout
Bad
Design
LengthySetups
8/14/2019 JIT & Kaizen-Fundas
16/27
Lower Levels Of
Inventory To ExposeProblems
Poor
Quality
Unreliable
Supplier
Machine
BreakdownInefficient
Layout
Bad
Design
Lengthy
Setups
8/14/2019 JIT & Kaizen-Fundas
17/27
SMED Principles1. Separate internal setup from
external setup
2. Convert internal setup to externalsetup
3. Streamline all aspects of setup
4. Perform setup activities in parallelor eliminate them entirely
8/14/2019 JIT & Kaizen-Fundas
18/27
Reducing Setup Time Preset desired settings
Use quick fasteners Use locator pins
Prevent misalignments
Eliminate tools
Make movements easier
8/14/2019 JIT & Kaizen-Fundas
19/27
Quality At The
Source Jidoka is authority to stop
production line Andon lights signal quality
problems
Visual control makes problemsvisible
Poka-yoke prevents defects
8/14/2019 JIT & Kaizen-Fundas
20/27
Kaizen Continual improvement
Requires total employment involvement
Essence of JIT is willingness of All to spot quality problems
halt production when necessary
generate ideas for improvement analyze problems
perform different functions
8/14/2019 JIT & Kaizen-Fundas
21/27
Total Productive
Maintenance (TPM) Breakdown maintenance
repairs to make failed machine
operational
Preventive maintenance
system of periodic inspection &
maintenance to keep machinesoperating
TPM combines preventivemaintenance & total quality concepts
8/14/2019 JIT & Kaizen-Fundas
22/27
TPM Requires
Management To Design products that can be easily
produced on existing machines
Design machines for easier operations,changeover, maintenance
Train & retrain workers to operate
machines Design preventive maintenance plan
spanning life of machine
8/14/2019 JIT & Kaizen-Fundas
23/27
Visual Control
Library shelfWork station
Visual kanbansTool board
Machine controls
BetterGood Best
30-50
How
to
sensor
Trends In Supplier
8/14/2019 JIT & Kaizen-Fundas
24/27
Trends In SupplierPolicies
1. Locate near to the customer
2. Use small, side loaded trucks and ship mixedloads
3. Consider establishing small warehouses near tothe customer or consolidating warehouses withother suppliers
4. Use standardized containers and make deliveriesaccording to a precise delivery schedule
5. Become a certified supplier and accept paymentat regular intervals rather than upon delivery
8/14/2019 JIT & Kaizen-Fundas
25/27
Benefits Of JIT
1. Reducedinventory
2. Improved quality3. Lower costs
4. Reduced space
requirements5. Shorter lead time
6. Increasedproductivity
7. Greater flexibility
8. Better relations with
suppliers9. Simplified scheduling
and control activities
10. Increased capacity
11. Better use of humanresources
12. More product variety
8/14/2019 JIT & Kaizen-Fundas
26/27
JIT Implementation
Use JIT to finely tune an
operating system From Japan-TPS to Allover in
World
JIT requires evolving all time JIT is for everyone
8/14/2019 JIT & Kaizen-Fundas
27/27
JIT In Services
Competition on speed & quality
Multifunctional department storeworkers
Work cells at fast-food restaurants
Just-in-time Sale of - ?
Construction firms receiving materialjust as needed