Kaizen in JIT Production System

KAIZEN in Just-In-Time
Production System
Hasan Haider, NPO Pakistan
The challenges for our Industry
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We need
need to
to be
be able
able to
to do
do three
three things
things well,
well, all
all at
at the
the same
same time!
time!
We
Reduce Lead Time
Improve Quality
Faster
Better
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Reduce Cost
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Production Costs
Customer Price
Net Margin
Cheaper
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KAIZEN in Just-In-Time
Production System
Jay-eye-tea
JIT
Toyota Production System

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What issue/concept will be most

important to you in the 1990s ?
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Reduction of Production Lead Time
Source: Sanno College Seisan-shi Textbook
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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.
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Meeting the Challenge
mer
o
t
s
u
C
lier
Supp ships
ion
Relat
Visual
Controls
Multi-
Time
ation
m
o
n
o
Aut
Sa
fe
ty
Ma
int
en
an
ce
Work
Cells
Ta k t
Process
Lev
el
5S
Dem
and
ll
a
m
S
Lot
Size
em
t
s
Sy
l
l
Pu
Spiri
t
up
S et
ion
t
c
u
Red
On
Pie e
c
Flo e
w
Sta
nda
rd
Wo
rk
Ba Lin
la e
n
g ci n
JIT - A set of tools that fit together
y
Qualit
an ce
r
u
s
s
A
Attack
On
Waste
ke
a
t
Mis
ing
f
o
Pro
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JIT - A Strategy Based on Lead Time

Adding Value
Opportunity
Lead Time
A strategic focus to economically make

drastic reductions in lead times to better serve
the customer.
JIT - A Toolset For Eliminating Waste

JIT Tools used
to identify and
eliminate
waste from the
process.
$
$ $
$
$
Same Value-Add
Result: Shorter
lead times,
reduced costs.
Reduced lead time

Reduced costs
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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 conference
room.
More ideas are better, especially from people
close to the problem.
Follow up to make sure the idea is working.
Improvement is endless.
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The Spirit of Improvement
Purpose of a Kanban System

1) Control of inventory movement.
2) Authorize production.
3) Regulate amount of inventory in the
system.
4) Provide a visual control that makes
overproduction obvious.
5) A tool for driving continuous
improvement.
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Rules for Kanban Systems

1) Pull from the downstream process (or customer)
drives the system.
2) All product or inventory is under kanban control.
3) Only an empty kanban authorizes production.
4) Never pass a known defect downstream.
5) Use gradual kanban reductions to drive improvement.
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Kanban
al
Is a signal that:
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Authorizes production
Authorizes movement
Limits inventory
The signal can be a:
Card
Square
Box
Pigeon hole
Light
Etc.
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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
= Number of Kanbans
Units per Kanban
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Pull Production System

Definition
A customer driven system that produces and
moves a product/service only when the
customer needs it
Kanban
1
Work
Center A
Kanban
2
Work
Center B
Kanban
3
Work Flow
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Push System
Pull System
Push and Pull System
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Supermarket Concept & KANBAN

System
KANBAN
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Just-In-Time (JIT) system

The concept of producing or conveying
only those units needed,
just when they are needed,
in just the amount needed,
at all stages of production.
By Toyota Motor Company
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Mistake Proofing Overview
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Poka-Yoke
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Mistake-proof (Poka-yoke)
Note: Poka ----- Carelessness; Absent-mind
This refers to the thoughtful use of

devices which eliminates operators
careless mistakes.
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Yoke----- Elimination
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Purpose
The mistake-proofing process
prevents mistakes before they
create defects.
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Mistake-Proofing
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What is Poka-Yoke Mistake-Proofing ?

An Organized Approach to a Common Sense
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Mistake Proofing Is a Philosophy That:
Recognizes People Forget and Make Errors
Uses Common Sense (Mistake Proofing) Ideas
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Way of Eliminating Defects
and Methods in Product and Process Design to

Eliminate Human and Mechanical Errors
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Why do mistake-proofing?
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Improve quality
Eliminate rework
Reduce cost
Improve schedule performance (especially
in relation to the predictability of cycle
times
Zero Quality Control (Zero Defects)
Total Customer Satisfaction
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Mistake-Proofing
Quality, Cost, Delivery, Safety, Morale

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Benefits and Results

Results
Benefits
Makes it easy to do the

right things in the right
order in the right way.
Prevents accidentally
doing the wrong things
in the wrong order in the
wrong way
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Improves quality
Reduces costs
Improves on-time delivery
Reduces or
eliminates 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
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Beeper to Indicate the Lights Are Left on When the Keys Are
Removed From the Ignition Switch
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Cruise Control Which Shuts off When the Brakes Are Applied
Turn Signal Warning Beep When Left on
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Examples of Common Devices

Safety Features in the Products
Gas Furnace With an Interlock Switch
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Carrier Produces:
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That Shuts Down the Furnace When

Thermostat Which Prevents Heat
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Panels Are Removed

and Cool From Being Turned on at
the Same Time
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Examples of Common Devices
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In Manufacturing:
Safety Devices on Presses
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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
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Palm Buttons
Light Curtains
Brake Monitors
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Why Do Mistake Proofing ?

Customers Demand 100% Defect Free Products
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Cost Pressures Dont Allow for Continued Mistakes
Scrap
Rework
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100% Inspection Wont Provide 100% Defect Free

Products
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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 Hasan Haider, NPO Pakistan
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100% Inspection Exercise
John Foster
3-21-92
Quality Engineer
Date
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Please Find and Count All the Fs

in This Letter
Finished Files Are The Result Of

Years Of Scientific Study Combined
With The Experience Of Years
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7 Fs Total - How Many Did You Each Find ?
John Foster
3-21-92
Quality Engineer
Date
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Please Find and Count All the Fs

in This Letter
Finished Files Are The Result Of

Years Of Scientific Study Combined
With The Experience Of Years
29
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Is 99.9% Quality Good Enough for You ?

If It Is, Then You Wont Mind 0.1%
Doctors in New York State Hospitals Drop
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Ill do better
next time!
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Defectives:
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288 Babies Per Year

Post Offices in New York State Lose 61,626
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Pieces of Mail Per Day
Chicago OHare International Airport Has

1,264 Unsafe Arrivals / Departures Per Year
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Examples of Errors Vs. Defects

Error - (Cause)
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Leave the Iron on Then

Leave for Work
Defect - (Effect)
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Pump Diesel Fuel Into Your

Gas Tank
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Run a Red Light
Not Setting the Timer

Properly on Your Toaster
Placing the Original in Your

Copier Face up.
Running Out of Ink on Your
Date Coder
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7 Step Mistake Proofing Process
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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 or
Detect Error Conditions.
7. Trial and Error Perfection of Original Mistake-proof Device
Until Solution Eliminates Defect.
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Types of Mistake-Proof Devices
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A list of Mistake-proof devices, certainly not all inclusive, that can be

used to respond to Red Flags and prevent errors and/or defects:
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Template
Limit Switch / Microswitch
Counter
Odd-part-out Method
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2.
3.
4.
5.
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1. Guide / Reference / Interference Other Prevention Techniques:

Rod or Pin
6.
7.
8.
9.
Sequence Restriction
Standardize and Solve
Critical Condition Indicator
Detect Delivery Chute
1. Eliminate the Condition
2. Redesign for Symmetry

3. Redesign for Asymmetry
Mistake-proof Your Mistakeproof
10. Stopper / Gate

11. Sensor
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Detecting and Avoiding Defects
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What are the Five Best Mistake-Proof Devices?

Human errors are usually inadvertent. Mistake-proof devices
help 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 or
avoiding defects caused by human errors.
UPPER DIE
GUIDE PINS
Guide Pins of Different

Sizes
LOWER DIE
Error Detection and

Alarms
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Detecting and Avoiding Defects - cont...

Limit Switches
PRESS
LIMIT SWITCH DETECTS
CORRECT PLACEMENT
PRODUCT
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TO OPERATING
CIRCUIT
CLEAR BUTTON
Counters
DIGITAL COUNTER
Checklists
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Mistake Proofing Example

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Before Mistake-Proofing
Locating
Angles
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Locating
Angles
After Mistake-Proofing
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Correct
Locating
Angles
Guide Pin
Incorrect
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Omitted Washer
Container
During assembly, lockwashers are frequently

omitted. Without the lockwashers, the bolts can
loosen.
The correct number of each part required for the

operation is precounted and provided in a
container.
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Correct
Fire
Extinguisher
Reservoir
Bottles
Hose to Area B
Hose to Area A
Hose to Area A
Fire
Extinguisher
Reservoir
Bottles
Hose to Area B
Incorrect
Fire
Extinguisher
Reservoir Hose to
Area B
Bottles
Female
Male
Different size
connectors
Hose to Area A
Hose connections can be reversed. If a fire

occurred in Area A, Area B would be doused.
By redesigning the connectors to two different

sizes and types (female and male), it is no
longer possible to mix up hose connections.
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Manual measuring and layout of trim periphery

Locating
Holes
Panel Trim
Lines
Trim
Template
Locating
Holes
Results in inaccurate location of trim lines,

creating a defective part when the part is
trimmed.
Panel Trim
Lines
Use of template allows accurate layout of trim

lines.
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Covers were frequently scratched when the screwdrivers

slipped out of the screw slot and slid against the plastic
covers.
The cause of the trouble was scrutinized and

a change was made in the shape of the screw
slot to prevent the screwdriver from slipping.
Scratches caused by the screwdriver slipping
have been completely eliminated.
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Poka-yoke Example 1
Screw driver slips

and scratches the
Source: Poka-yoke Daizukan Nikkan-kogyo
product.
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Poka-yoke Example 2
Fool-proof device
Non-defective
Defective
Source: Poka-yoke Daizukan Nikkan-kogyo

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Analysis of Carelessness
Kanebo Chemical, 1989
Wrong operations
23%
Negligence
(Forgetfulness)
48%
Source: Poka-yoke activities Kanebo Chem.,1991
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Jidoka refers to the ability of production

equipment, including a single machine,
to sense a malfunction of the machine.
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Auto-nomation (Jidoka)
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Autonomation (Jidoka): Automation

Stop!
I dont know.
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with a human touch
Jidoka
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Simple automation
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tri
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Single minute exchange of die

(SMED)
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goal of single minute set-up

movement is to reduce the setup time to less than 10 minutes.
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Stamping Machine
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The Trick of the Magic
Advanced Preparation
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Masking
tape
Paint an arrow
Trash can
Spreadsheet
Example (1)
Source: The Japan HR Association
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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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Seven Wastes
1.
2.
3.
4.
5.
6.
7.
Waste from over-production

Waste of waiting time
Transportation waste
Processing waste
Inventory waste
Waste of motion
Waste from product defectives
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KAIZEN in Just-In-Time

Hasan Haider, NPO Pakistan

The challenges for our Industry

Reduce Lead Time

Hasan Haider, NPO Pakistan

Toyota Production System

What issue/concept will be most

Reduction of Production Lead Time

Hasan Haider, NPO Pakistan

Source: Sanno College Seisan-shi Textbook

Requires a new way of thinking.

Need to do more than talk.

Meeting the Challenge

Hasan Haider, NPO Pakistan

Hasan Haider, NPO Pakistan

JIT - A set of tools that fit together

JIT - A Strategy Based on Lead Time

A strategic focus to economically make

JIT - A Toolset For Eliminating Waste

Reduced lead time

Improvement is everyone's job.

The Spirit of Improvement

Hasan Haider, NPO Pakistan

Purpose of a Kanban System

Rules for Kanban Systems

Hasan Haider, NPO Pakistan

The signal can be a:

Hasan Haider, NPO Pakistan

How Many Kanbans?

Units per Kanban

Hasan Haider, NPO Pakistan

Pull Production System

Hasan Haider, NPO Pakistan

Supermarket Concept & KANBAN

Hasan Haider, NPO Pakistan

Just-In-Time (JIT) system

Mistake Proofing Overview

Hasan Haider, NPO Pakistan

This refers to the thoughtful use of

Hasan Haider, NPO Pakistan

Hasan Haider, NPO Pakistan

What is Poka-Yoke Mistake-Proofing ?

Mistake Proofing Is a Philosophy That:

Recognizes People Forget and Make Errors

Uses Common Sense (Mistake Proofing) Ideas

Way of Eliminating Defects

and Methods in Product and Process Design to

Hasan Haider, NPO Pakistan

Quality, Cost, Delivery, Safety, Morale

Benefits and Results

Makes it easy to do the

Hasan Haider, NPO Pakistan

Mistake-Proofing in Everyday Life

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.

Turn Signal Warning Beep When Left on

Hasan Haider, NPO Pakistan

Examples of Common Devices

That Shuts Down the Furnace When

Panels Are Removed

Hasan Haider, NPO Pakistan

Examples of Common Devices

Fire Drills, Safe Exit Plans