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Lean
Manufacturing
Seven Wastes
Overproduction
Queues
Transportation
Inventory
Motion
Over-processing
Defective product
Prof. Sanjay Jharkharia
Key
Traditional View of
Manufacturing
JIT Manufacturing
Philosophy
The
Elements of JIT
Manufacturing
Eliminating
waste
Enforced problem solving and continuous
improvement
People make JIT work
Total Quality Management (TQM)
Parallel processing
Kanban (pull type) production system
JIT purchasing
Reducing inventories
Working toward repetitive manufacturing
Prof. Sanjay Jharkharia
Eliminating Waste in
Manufacturing
Make
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Uncovering Production
Problems
Unreliable
Vendors
Scrap
Prof. Sanjay Jharkharia
Capacity
Imbalances
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Uncovering Production
Problems
Reducing inventory reveals
problems to be corrected.
Unreliable
Vendors
Scrap
Prof. Sanjay Jharkharia
Capacity
Imbalances
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design/processes
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Kanban Production
Control
At
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Conveyance (Withdrawal)
Kanban
Conveyance Kanban Card
Part number to produce: M471-36
Card number: 2 of 5
To work center: 35
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Production Kanban
Production Kanban Card
Part number to produce: M471-36
Card number: 4 of 5
To work center: 35
Materials required:
Material no. 744B
Part no. B238-5
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Benefits of JIT
Inventory
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JIT Partnerships
Quantities
Share forecasts of demand
Frequent deliveries of small-lot quantities
Long-term contract
Minimal paperwork to release order (EDI or
the Internet)
Little or no permissible overage or underage
Suppliers package in exact quantities
Suppliers reduce production lot sizes
Prof. Sanjay Jharkharia
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Impact on Employees
Employees are cross trained for
flexibility and efficiency
Improved communications
facilitate the passing on of
important information about the
process
With little or no inventory buffer,
getting it right the first time is
critical
Prof. Sanjay Jharkharia
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Step 1
90 min
Step 2
Standardize and
improve tooling
(save 15 minutes)
Step 3
Step 4
Step 5
60 min
45 min
25 min
15 min
13 min
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Scheduling
Schedules must be communicated
inside and outside the organization
Level schedules
Process frequent small batches
Freezing the schedule helps stability
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Quality
Strong relationship
JIT cuts the cost of obtaining good
quality because JIT exposes poor quality
Because lead times are shorter, quality
problems are exposed sooner
Better quality means fewer buffers and
allows simpler JIT systems to be used
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Employee
Empowerment
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The 5 Ss
Sort/segregate
Simplify/straighten
Shine/sweep
Standardize
Sustain/self discipline
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Questions!
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