Академический Документы
Профессиональный Документы
Культура Документы
GROUP NO : 06
Mayur Avhad - 22 Navketan Gaikwad 24 Pratik Gole 31 Rajesh Sharma 35 Sushil Pawar 60 Amit Prasad -
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Space
Labor Inventory
Money Time
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1. ELIMINATE WASTE
Waste is anything that does not add value from the customer point of view
Storage, inspection, delay, waiting in queues, and defective products do not add value and are 100% waste
Other resources such as energy, water, and air are often wasted Efficient, sustainable production minimizes inputs, reduces waste
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2. REMOVE VARIABILITY
JIT systems require managers to reduce variability caused by both internal and external factors
Variability is any deviation from the optimum process Inventory hides variability Less variability results in less waste
Sources of Variability
1. 2. 3. Incomplete or inaccurate drawings or specifications Poor production processes resulting in incorrect quantities, late, or nonconforming units Unknown customer demands
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3. IMPROVE THROUGHPUT
The time it takes to move an order from receipt to delivery The time between the arrival of raw materials and the shipping of the finished order is called manufacturing cycle time A pull system increases throughput By pulling material in small lots, inventory cushions are removed, exposing problems and emphasizing continual improvement Manufacturing cycle time is reduced Push systems dump orders on the downstream stations regardless of the need
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JUST-IN-TIME (JIT)
Powerful strategy for improving operations Materials arrive where they are needed when they are needed
Identifying problems and driving out waste reduces costs and variability and improves throughput
Requires a meaningful buyer-supplier relationship
Big lot sizes Lots of inventory PUSH material to next stage
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Lower per unit cost Big pushes of finished goods to warehouses or customers
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ELEMENTS OF JIT
JIT manufacturing focuses on production system to achieve value-added manufacturing
Flexible resources
Efficient facility layouts
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KANBAN
Kanban is the Japanese word for card The card is an authorization for the next container of material to be produced A sequence of kanbans pulls material through the process Many different sorts of signals are used, but the system is still called a kanban
Final assembly
Finished goods
Customer order
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KANBAN CARD
Signal to Produce
Workcenter A Workcenter B
Signal to Pull
Workcenter A Workcenter B
Kanban Card
When a container is opened by Workcenter B, its kanban card is removed and sent back to Workcenter A. This is a signal to Workcenter A to produce another box of parts.
Empty box sent back. Signal to pull another full box into Workcenter B. Question: How many kanban cards here? Why?
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Example : Hourly demand = 300 units Lead time = 3 hours Each container holds 300 units Assuming no variation in lead-time or demand (x = 0): y = (300 3) / 300 = 3 kanban cards
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Weekly Production Required A B C D E Traditional Production Plan Monday Tuesday AAAAA BBBBB AAAAA BBBBB JIT Plan with Level Scheduling Monday Tuesday AABBBB AABBBB CDEE CDEE
10 units 20 units 5 units 5 units 10 units Wednesday BBBBB BBBBB Wednesday AABBBB CDEE Thursday DDDDD CCCCC Thursday AABBBB CDEE Friday EEEEE EEEEE Friday AABBBB CDEE
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FLEXIBLE RESOURCES
Moveable, general purpose equipment: Portable equipment with plug in power/air Drills, lathes, printer-fax-copiers, etc. Capable of being setup to do many different things with minimal setup time
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U-shaped lines: (allows material handler to quickly drop off materials & pick up finished work)
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BENEFITS OF JIT
Reduction in inventories Improved quality Reduced space requirements Shorter lead times Lower production costs Increased productivity Increased machine utilization Greater flexibility
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THANK YOU!!!
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