Академический Документы
Профессиональный Документы
Культура Документы
by John Loucks
2
Overview
3
APICS Definition of JIT
4
APICS Definition of JIT
5
JIT Synonyms
6
APICS Definition of Lean Manufacturing
7
Time-Based Competition
8
Order-to-Delivery Cycle
Manufacturing
Cumulative Lead Time
Custo- Manufacturing Distri-
Engi- Lead Times bution and
mer Order Sched-
neering
Places Entry uling Purchasing Customer
Design
Order Lead Times Service
Order-to-Delivery Cycle
9
Traditional View of Manufacturing
10
JIT Manufacturing Philosophy
11
Capacity Utilization
50
Traditional
Manufacturing
40
30
20 JIT
Manufacturing
10
% Capacity
Utilization
10 20 30 40 50 60 70 80 90 100
12
Increasing Production Capacity
Reduces Manufacturing Lead Times
Only slight increases in production capacities can
lead to:
Significant reduction of manufacturing lead times
Significant reduction of work-in-process inventory
Queuing theory can be used to analyze waiting-line
production problems
13
Necessary Production Capacity
14
Work-in-Process Inventory
15
Example: Necessary Production Capacity
16
Example: Necessary Production Capacity
17
Example: Reduction in WIP
18
Example: Reduction in WIP
20
Changes Required for JIT
21
Elements of JIT Manufacturing
Eliminating waste
Enforced problem solving and continuous
improvement
People make JIT work
Total Quality Management (TQM)
Parallel processing
Kanban production control
JIT purchasing
Reducing inventories
Working toward repetitive manufacturing
22
Eliminating Waste in Manufacturing
23
Problem Solving and Continuous Improvement
25
People Make JIT Work
26
TQM and JIT
27
Parallel Processing
29
Kanban Production Control
30
Kanbans and Other Signals
31
Kanban Cards
32
Kanban Cards
Materials required:
Material no. 744B Storage location: NW48C
Part no. B238-5 Storage location: NW47B
33
How Kanban Operates
emptied.
He finds a full container of the needed part in storage.
In-process
Upstream Downstream
storage
Work Center #1 Work Center #2
Parts Flow
35
Containers in a Kanban System
UT(1+P)
N=
C
N = Total number of containers between 2 stations
U = Usage rate of downstream operation
T = Average elapsed time for container to make
entire cycle
P = Policy variable indicating efficiency... 0 - 1
C = Capacity (number of parts) of standard container
37
Example: Number of Containers
38
Example: Number of Containers
Number of Containers, N
N = UT(1 + P) / C
= 165(0.6)(1 + 0.2) / 24
= 99(1.2) / 24
= 118.8 / 24
= 4.95 or 5 containers
39
Essential Elements of JIT Purchasing
41
Reducing Inventories
through Setup Time Reduction
Central to JIT is the reduction of production lot sizes
so that inventory levels are reduced.
Smaller lot sizes result in more machine setups
More machine setups, if they are lengthy, result in:
Increased production costs
Lost capacity (idle machines during setup)
The answer is: REDUCE MACHINE SETUP TIMES
42
Setup Time Required for an EOQ
2DS p
EOQ =
C p-d
where: D = annual demand rate
d = daily demand rate
p = daily production rate
C = carrying cost per unit per year
S = cost per setup
more
43
Setup Time Required for an EOQ
C(EOQ) p-d
2
S=
2D p
The setup time can be derived from the setup cost, S:
S
Setup Time =
Labor rate
44
Example: Setup Time Required
45
Example: Setup Time Required
46
Example: Setup Time Required
47
Working Toward Repetitive Manufacturing
48
Working Toward Repetitive Manufacturing
49
Benefits of JIT
50
Wrap-Up: World-Class Practice
51
End of Chapter 12
52