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Lean
operations
and JIT
Source: Tibbet and Britten
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Operations
strategy
Design
Operations
management
Improvement
Planning and
control
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Synonyms
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
stage A
buffer
inventory
stage B
buffer
inventory
stage
C
JIT approach
orders
orders
stage B
stage A
deliveries
stage C
deliveries
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
focus on producing
only when needed
JIT
approach
fewer stoppages
focus on high
capacity utilization
lower capacity
utilization, but
more stoppages
because of
problems
more production
at each stage
high inventory
means less chance
of problems being
exposed and solved
extra production
goes into inventory
because of continuing
stoppages at stages
low inventory so
problems are
exposed and
solved
no surplus
production goes
into inventory
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
JIT definitions
JIT aims to meet demand instantly, with perfect quality and no waste
More fully:
Improved overall productivity and elimination of waste
Source: Empics
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Involve everyone
Continuous
improvement
TPM
Set-up reduction
Operations focus
Visibility
Flow layout
JIT supply
JIT as a method of
planning and control
Pull scheduling
Kanban control
Levelled scheduling
Mixed modelling
Synchronization
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
The 5 Ss
Sort (Seiri) Eliminate what is not needed and keep what is needed.
Straighten (Seiton) Position things in such a way that they can be
easily reached whenever they are needed.
Shine (Seiso) Keep things clean and tidy; no refuse or dirt in the work
area.
Standardize (Seiketsu) Maintain cleanliness and order perpetual
neatness.
Sustain (Shitsuke) Develop a commitment and pride in keeping to
standards.
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Inventory
level
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Waste (muda)
Activities:
operation
movement
Types of waste:
over-production
waiting time
transport
inspection
process
inventory
delay
storage
motion
defective goods
influencing the throughput efficiency
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
productivity
problems
WIP
Defective
materials
Scrap
Rework
Downtime
WIP
Defective
materials
productivity
problems
Scrap
Rework
Downtime
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Small machines
The conventional Western approach is to purchase large
machines to get economies of scale.
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
emphasis:
flexibility
economies of scope
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
emphasis:
continuous improvement in
small steps, to expose waste
and eliminate it
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
complex
structures
PERT
MRP
JIT and/or
MRP
simple
structures
JIT
simple routings
complex
routings
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007
Slack, Chambers and Johnston, Operations Management 5th Edition Nigel Slack, Stuart Chambers, and Robert Johnston 2007