Kaizen in JIT Production System

7/25/2019 Kaizen in JIT Production System

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Hasan Haider, NPO Pakistan 1

KAIZEN in Just-In-Time

Production System


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Reduce Cost

Cheaper

Customer Price

Net Margin

Production Costs

Faster

Reduce Lead Time Improve Quality

Better

The challenges for our Industry

We need to be able to do three things well, all at the same time!

We need to be able to do three things well, all at the same time!

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KAIZEN in Just-In-TimeProduction System

! Toyota Production System

Jay-eye-tea

J I T1

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Reduction of Production Lead Time

Source: Sanno CollegeSeisan-shi Textbook

What issue/concept will be mostimportant to you in the 1990s ?

1

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Meeting the Challenge

! Requires a new way of thinking.

! Training in new methods.

! Leadership and commitment at all levels.! Implementation - do it.

! Need to do more than talk.

! We learn by doing.

! Improvements dont have to be expensive.df

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Setup

Setup

Reducti

on

Reducti

on

Autonomat

ion

Autonomat

ion LevelLevel

Demand

Demand

SpiritSpirit

5S5S

Standard

StandardWorkWork

PullSys

tem

PullSys

tem

Safety

Safety

Customer

Customer

SupplierSupplier

Relationshi

psRelati

onships

Maintenance

Maintenance

VisualVisual

Controls

Controls

Mistake

Mis

take

Proofin

gPro

ofing

Takt

Takt

TimeTime

WorkWork

CellsCells MultiMulti--

ProcessProcess

L

ine

L

ine

Balan

cin

Balan

cin

gg

AttackAttack

OnOn

WasteWaste

SmallSmall

Lot

Lot

SizeSize

QualityQuality

AssuranceAssurance

OneOnePiece

PieceFlowFlow

JIT - A set of tools that fit together


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JIT - A Strategy Based on Lead Time

Lead Time

Adding Value

Opportunity

A strategic focus to economicallymakedrastic reductions in lead times to better servethe customer.


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JIT - A Toolset For Eliminating Waste

JIT Tools usedto identify andeliminatewaste from theprocess. $$

$ $

$$

$ $$

Same Value-Add

Reduced lead time

Reduced costs

Result: Shorterlead times,reduced costs.


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The Spirit of Improvement

! Improvement is everyone's job.

! Think of ways to make ideas work.

! Dont say cant.

! 50% improvement is OK.! Dont substitute money for brains.

! Ask Why?, five times.

! Improvement is not made from a conferenceroom.

! More ideas are better, especially from peopleclose to the problem.

! Follow up to make sure the idea is working.

! Improvement is endless.

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Purpose of a Kanban System

1) Control of inventory movement.

2) Authorize production.

3) Regulate amount of inventory in thesystem.

4) Provide a visual control that makesoverproduction obvious.

5) A tool for driving continuousimprovement.


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Rules for Kanban Systems

1) Pull from the downstreamprocess (or customer)

drives the system.

2) All product or inventory is under kanbancontrol.

3) Only an emptykanbanauthorizes production.

4) Never pass a known defect downstream.

5) Use gradual kanbanreductions to drive improvement.


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Kanban

Is a signal that:

Authorizes production

Authorizes movement

Limits inventory

The signal can be a:

Card

Square Box

Pigeon hole

Light

Etc.p

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How Many Kanbans?

(True Lead Time + Safety Time) = Total Time

Total Time x Production Requirement = Units in Pipeline

Units in Pipeline

Units per Kanban

= Number of Kanbans


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Pull Production System

Definition A customer driven system that produces and

moves a product/service onlywhen thecustomer needs it

Work Flow

Kanban1

Kanban2

Kanban3

WorkCenter A

WorkCenter B


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Push System

Pull System

Push and Pull System2


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KANBAN

Supermarket Concept & KANBAN

System

1


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By Toyota Motor Company

The concept of producing or conveying

only those units needed,

at all stages of production.

just when they are needed,

in just the amount needed,

Just-In-Time (JIT) system

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" Mistake Proofing Overview" Poka-Yoke

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! This refers to the thoughtful use ofdevices which eliminates operators

careless mistakes.

Note: Poka ----- Carelessness; Absent-mind

Yoke----- Elimination

Mistake-proof (Poka-yoke)

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Mistake-Proofing! Purpose

! The mistake-proofing processprevents mistakes before theycreate defects.

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! An Organized Approach to a Common Sense

Way of Eliminating Defects

! Mistake Proofing Is a Philosophy That:

! Recognizes People Forget and Make Errors

! Uses Common Sense (Mistake Proofing) Ideas

and Methods in Product and Process Design to

Eliminate Human and Mechanical Errors

What is Poka-Yoke Mistake-Proofing ?

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Mistake-Proofing

! Why do mistake-proofing?

! Improve quality

! Eliminate rework

! Reduce cost

! Improve schedule performance (especially

in relation to the predictability of cycle

times

! ZeroQuality Control (Zero Defects)

! Total Customer Satisfaction

! Quality, Cost, Delivery, Safety, Morale

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Benefits and ResultsBenefits

! Makes it easy to do theright things in the rightorder in the right way.

! Prevents accidentallydoing the wrong thingsin the wrong order in thewrong way

Results

! Improves quality

! Reduces costs

! Improves on-time delivery

! Reduces oreliminates accidents

! Improves morale

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Mistake-Proofing in Everyday Life

! Car safety belt warning light or buzzer.

! Clothes iron that shuts itself off if left on inadvertently.

! Garage door opener with safety reversing switch.

! A car that cannot be started in gear.

! Microwave ovens that will not start with the door open

! Beeper to Indicate the Lights Are Left on When the Keys AreRemoved From the Ignition Switch

! Cruise Control Which Shuts off When the Brakes Are Applied

!

Turn Signal Warning Beep When Left on

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# Safety Features in the Products

Carrier Produces:

! Gas Furnace With an Interlock Switch

That Shuts Down the Furnace WhenPanels Are Removed

! Thermostat Which Prevents Heat

and CoolFrom Being Turned on at

the Same Time

Examples of Common Devices

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# In Manufacturing:

Safety Devices on Presses

Palm Buttons

Light Curtains

Brake Monitors

Fire Drills, Safe Exit Plans

Pressure Switches, Monitors

Panic Door Hardware on All Exterior Doors

Fixtures Which Prevent Parts From Being

Incorrectly Positioned Tools Which Reach a Specified Torque then

Shut off

Examples of Common Devices

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Customers Demand 100% Defect Free Products

# 100% Inspection Wont Provide 100% Defect Free

Products

# Cost Pressures Dont Allow for Continued Mistakes

Scrap

Rework

Missed Schedules

# Lean Manufacturing Will Not Tolerate Mistakes

One Piece Flow Demands Good Quality Parts

All the Time

Batch Processing Can Hide Mistakes With

Excess Inventory

Why Do Mistake Proofing ?

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100% Inspection Exercise

Quality Engineer Date

John Foster 3-21-92

Finished Files Are The Result Of

Years Of Scientific Study CombinedWith The Experience Of Years

Please Find and Count All the Fsin This Letter

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Please Find and Count All the Fsin This Letter

Quality Engineer Date

John Foster 3-21-92

77 Fs Total - How Many Did You Each Find ?

Finished Files Are The Result Of

Years Of Scientific Study CombinedWith The Experience Of Years

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If It Is, Then You Wont Mind 0.1%

Defectives:

! Doctors in New York State Hospitals Drop

288 Babies Per Year

! Post Offices in New York State Lose 61,626

Pieces of Mail Per Day

! Chicago OHare International Airport Has

1,264 Unsafe Arrivals / Departures Per Year

Ill do betternext time!

Is 99.9% Quality Good Enough for You ?

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Leave the Iron on ThenLeave for Work

Pump Diesel Fuel Into YourGas Tank

Run a Red Light

Not Setting the TimerProperly on Your Toaster

Placing the Originalin YourCopier Face up.

Running Out of Ink on YourDate Coder

Error - (Cause) Defect - (Effect)

?

Examples of Errors Vs. Defects

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7 Step Mistake Proofing Process

1. Describe the Defect in Detail.

2. Identify Process or Operation Where Defect Can First Be

Discovered - Where Defect has Actually Been Created.

3. Map the Sequence of Tasks by Reviewing Current Method or

Procedures (the Way It Is Supposed to Be Done).4. Observe the Process (the Way It Is Actually Being Done).

5. Identify Errors - Gaps Between #3 and #4 - the Differences

Between How We Should Do It and How We Actually Do It

(Theory Vs. Actual).

6. Identify Mistake Proof Device(s) Required to Prevent orDetect Error Conditions.

7. Trial and Error Perfection of Original Mistake-proof Device

Until Solution Eliminates Defect.

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A list of Mistake-proof devices, certainly not all inclusive, that can beused to respond to Red Flags and prevent errors and/or defects:

Other Prevention Techniques:

1. Eliminate the Condition

2. Redesign for Symmetry

3. Redesign for Asymmetry

Mistake-proof Your Mistake-proof

1. Guide / Reference / InterferenceRod or Pin

2. Template

3. Limit Switch / Microswitch

4. Counter

5. Odd-part-out Method

6. Sequence Restriction

7. Standardize and Solve

8. Critical Condition Indicator9. Detect Delivery Chute

10. Stopper / Gate

11. Sensor

Types of Mistake-Proof Devices

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What are the Five Best Mistake-Proof Devices?Human errors are usually inadvertent. Mistake-proof deviceshelp us avoid defects, even when inadvertent errors are made.Mistake-proofing helps build quality into processes.

Here are five examples of mistake-proofing for detecting oravoiding defects caused by human errors.

1Guide Pins of DifferentSizes

2Error Detection andAlarms

UPPER DIE

GUIDE PINS

LOWER DIE

Detecting and Avoiding Defects

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3 Limit Switches

4Counters

5 Checklists

PRODUCT

PRESS

TO OPERATINGCIRCUIT

LIMIT SWITCH DETECTSCORRECT PLACEMENT

CLEAR BUTTON

DIGITAL COUNTER

Detecting and Avoiding Defects - cont...

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Before Mistake-ProofingAfter Mistake-Proofing

Correct

Incorrect

LocatingAngles

LocatingAngles

LocatingAngles

Guide Pin

Mistake Proofing Example

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Before Mistake-Proofing After Mistake-Proofing

During assembly, lockwashers are frequentlyomitted. Without the lockwashers, the bolts canloosen.

The correct number of each part required for theoperation is precounted and provided in acontainer.

Container

Omitted Washer



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Hose connections can be reversed. If a fireoccurred in Area A, Area B would be doused.

By redesigning the connectors to two differentsizes and types (female and male), it is nolonger possible to mix up hose connections.

Hose to Area B

Hose to Area A

Hose to

Area B

Hose to Area A

Correct

Incorrect

FireFireExtinguisherExtinguisher

ReservoirReservoirBottlesBottles

FireFireExtinguisherExtinguisher

ReservoirReservoirBottlesBottles

Hose to Area B Hose to Area A

FireFireExtinguisherExtinguisherReservoirReservoir

BottlesBottles

Different size

connectors

Female Male



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Results in inaccurate location of trim lines,creating a defective part when the part istrimmed.

Use of template allows accurate layout of trimlines.

LocatingHoles

Panel TrimLines

Manual measuring and layout of trim periphery

Panel TrimLines

TrimTemplate

LocatingHoles



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Covers were frequently scratched when the screwdriversslipped out of the screw slot and slid against the plasticcovers.

The cause of the trouble was scrutinized anda change was made in the shape of the screwslot to prevent the screwdriver from slipping.Scratches caused by the screwdriver slippinghave been completely eliminated.



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! Screw driver slipsand scratches theproduct. Source: Poka-yoke Daizukan Nikkan-kogyo

Poka-yoke Example 1

1

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Source: Poka-yoke Daizukan Nikkan-kogyo

Non-defective

Defective

Fool-proof device

Poka-yoke Example 2


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Wrong operations 23%

Negligence 48%(Forgetfulness)

Source: Poka-yoke activities Kanebo Chem.,1991

Kanebo Chemical, 1989

Analysis of Carelessness


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! Jidoka refers to the ability of production

equipment, including a single machine,to sense a malfunction of the machine.

Auto-nomation (Jidoka)

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Hasan Haider, NPO Pakistan 45 1

Stop! I dont know.

Simple automationJidoka

Autonomation (Jidoka): Automation

with a human touch

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!The goal of single minute set-upmovement is to reduce the set-up time to less than 10 minutes.

Single minute exchange of die(SMED)

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Stamping Machine


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Advanced Preparation

The Trick of the Magic

1


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Maskingtape Paint an arrow

Trash can Spreadsheet

Source: The Japan HR AssociationExample (1)


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U-shaped washer Nut and bolt

Pear-shaped holes

Source: H. Hirano Me de mite wakaru JIT Seisan Hoshiki Nikkan-kogyo Shinbun,

Example (2)


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1. Waste from over-production

2. Waste of waiting time3. Transportation waste4. Processing waste5. Inventory waste

6. Waste of motion7. Waste from product defectives

5. Inventory waste

Seven Wastes

2

Date post:	28-Feb-2018
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Kaizen in JIT Production System

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