Slide Show Week #9 Chapter 11 Jit
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Transcript of Slide Show Week #9 Chapter 11 Jit
©The McGraw-Hill Companies, Inc., 2004
1
Chapter 11
Just-in-Time and Lean Systems
MANAGEMENT 520
CHAPTER 11
JUST IN TIME
AND LEAN SYSTEMS
©The McGraw-Hill Companies, Inc., 2004
2
• JIT Defined
• The Toyota Production System
• JIT Implementation Requirements
• JIT in Services
LESSON OBJECTIVES
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Just-In-Time (JIT)Defined
• JIT can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods)
• JIT also involves the elimination of waste in production effort
• JIT also involves the timing of production resources (i.e., parts arrive at the next workstation “just in time”)
©The McGraw-Hill Companies, Inc., 2004
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JIT and Lean Management• JIT can be divided into two terms: “Big JIT”
and “Little JIT”• Big JIT (also called Lean Management) is a
philosophy of operations management that seeks to eliminate waste in all aspects of a firm’s production activities: human relations, vendor relations, technology, and the management of materials and inventory
• Little JIT focuses more narrowly on scheduling goods inventory and providing service resources where and when needed
©The McGraw-Hill Companies, Inc., 2004
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JIT Demand-Pull Logic
Customers
Sub
Sub
Fab
Fab
Fab
Fab
Vendor
Vendor
Vendor
Vendor
Final Assembly
Here the customer starts the process, pulling an inventory item from Final Assembly…
Here the customer starts the process, pulling an inventory item from Final Assembly…
Then sub-assembly work is pulled forward by that demand…
Then sub-assembly work is pulled forward by that demand…
The process continues throughout the entire production process and supply chain
The process continues throughout the entire production process and supply chain
©The McGraw-Hill Companies, Inc., 2004
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The Toyota Production System
• Based on two philosophies:
• 1. Elimination of waste
• 2. Respect for people
Toyota’s run smoother than this!
©The McGraw-Hill Companies, Inc., 2004
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Waste in Operations
1. Waste from overproduction
2. Waste of waiting time
3. Transportation waste
4. Inventory waste
5. Processing waste
6. Waste of motion
7. Waste from product defects
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Minimizing Waste: Focused Factory
Networks
CoordinationSystem Integration
These are small specialized plants that limit the range of products produced (sometimes only one type of product for an entire facility)
These are small specialized plants that limit the range of products produced (sometimes only one type of product for an entire facility)
Some plants in Japan have as few as 30 and as many as 1000 employees
Some plants in Japan have as few as 30 and as many as 1000 employees
©The McGraw-Hill Companies, Inc., 2004
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Minimizing Waste: Group Technology (Part 1)
• Using Departmental Specialization for plant layout can cause a lot of
unnecessary material movement • Using Departmental Specialization for plant layout can cause a lot of
unnecessary material movement
Saw Saw
Lathe PressPress
Grinder
LatheLathe
Saw
Press
Heat Treat
Grinder
Note how the flow lines are going back and forthNote how the flow lines are going back and forth
©The McGraw-Hill Companies, Inc., 2004
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Minimizing Waste: Group Technology (Part 2)
• Revising by using Group Technology Cells can reduce movement and improve product flow
• Revising by using Group Technology Cells can reduce movement and improve product flow
Press
Lathe
Grinder
Grinder
A
2
BSaw
Heat Treat
LatheSaw Lathe
PressLathe
1
©The McGraw-Hill Companies, Inc., 2004
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Minimizing Waste: Uniform Plant Loading (heijunka)
Not uniform Jan. Units Feb. Units Mar. Units Total
1,200 3,500 4,300 9,000
Uniform Jan. Units Feb. Units Mar. Units Total
3,000 3,000 3,000 9,000
Suppose we operate a production plant that produces a single product. The schedule of production for this product could be accomplished using either of the two plant loading schedules below.
Suppose we operate a production plant that produces a single product. The schedule of production for this product could be accomplished using either of the two plant loading schedules below.
How does the uniform loading help save labor costs?How does the uniform loading help save labor costs?
or
©The McGraw-Hill Companies, Inc., 2004
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Minimizing Waste: Just-In-Time Production
• Management philosophy• “Pull” system though the plant• Hydraulic Push Systems
WHAT IT IS
• Employee participation• Industrial engineering/basics• Continuing improvement• Total quality control• Small lot sizes
WHAT IT REQUIRES
• Attacks waste• Exposes problems and bottlenecks• Achieves streamlined production
WHAT IT DOES
• Stable environment
WHAT IT ASSUMES
©The McGraw-Hill Companies, Inc., 2004
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Minimizing Waste: Inventory Hides Problems
Work in
process
queues
(banks)
Change
orders
Engineering design
redundancies
Vendor
delinquencies
Scrap
Design
backlogs
Machine
downtime
Decision
backlogsInspection
backlogs
Paperwork
backlog
Example: By identifying defective items from a vendor early in the production process the downstream work is saved
Example: By identifying defective work by employees upstream, the downstream work is saved
©The McGraw-Hill Companies, Inc., 2004
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Minimizing Waste: Kanban Production Control Systems
Storage Part A
Storage Part AMachine
Center Assembly Line
Material Flow
Card (signal) Flow
Withdrawal kanban
Once the Production kanban is received, the Machine Center produces a unit to replace the one taken by the Assembly Line people in the first place
This puts the system back were it was before the item was pulled
The process begins by the Assembly Line people pulling Part A from Storage
Production kanban
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Determining the Number of Kanbans Needed
• Setting up a kanban system requires determining the number of kanbans cards (or containers) needed
• Each container represents the minimum production lot size
• An accurate estimate of the lead time required to produce a container is key to determining how many kanbans are required
• Side Bar – In Japan space is a very important consideration since there is so little of it. This process saves on space requirements. May explain why concept NIH.
©The McGraw-Hill Companies, Inc., 2004
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Example of Kanban Card Determination: Problem Data
• A switch assembly is assembled in batches of 4 units from an “upstream” assembly area and delivered in a special container to a “downstream” control-panel assembly operation
• The control-panel assembly area requires 5 switch assemblies per hour
• The switch assembly area can produce a container of switch assemblies in 2 hours
• Safety stock has been set at 10% of needed inventory
©The McGraw-Hill Companies, Inc., 2004
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Example of Kanban Card Determination: Calculations
3or ,75.24
5(2)(1.1))(1
container theof Size
stockSafety timelead during demand Expected
C
SDL
k
3or ,75.24
5(2)(1.1))(1
container theof Size
stockSafety timelead during demand Expected
C
SDL
k
Always round up!
©The McGraw-Hill Companies, Inc., 2004
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Respect for People
• Level payrolls
• Cooperative employee unions
• Reliable Subcontractor networks
• Bottom-round management style (i.e., consensus management)
• Quality circles (Small Group Involvement Activities or SGIA’s)
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Toyota Production System’s Four Rules
1. All work shall be highly specified as to content, sequence, timing, and outcome
2. Every customer-supplier connection must be direct, and there must be an unambiguous yes-or-no way to send requests and receive responses
3. The pathway for every product and service must be simple and direct
4. Any improvement must be made in accordance with the scientific method, under the guidance of a teacher, at the lowest possible level in the organization
©The McGraw-Hill Companies, Inc., 2004
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JIT Implementation Requirements: Design Flow Process
• Link operations
• Balance workstation capacities
• Redesign layout for optimum flow
• Emphasize preventive maintenance
• Reduce lot sizes
• Reduce setup/changeover time
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JIT Implementation Requirements: Total Quality Control
• Worker responsibility
• SQC in place
• Enforce compliance
• Fail-safe methods (poka-yokes)
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JIT Implementation Requirements: Stabilize Schedule
• Level schedule
• Underutilize capacity
* Freeze Window (schedule is fixed an no changes permitted)
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JIT Implementation Requirements: Kanban-Pull
• Demand pull
• Backflush (periodically explode a BOM to determine what items went into the product
• Reduce lot sizes
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JIT Implementation Requirements: Work with Vendors
• Reduce lead times
• Frequent deliveries
• Project usage requirements
• Clear Quality expectations
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JIT Implementation Requirements: Reduce Inventory More
• Look for other areas to reduced materials
• Minimize Stores
• Minimize Transit
• Carousels
• Conveyors
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JIT Implementation Requirements: Improve Product Design
• Standard product configuration
• Standardize and reduce number of parts
• Align Process design with product design
• Quality expectations
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JIT Implementation Requirements: Concurrently Solve Problems
• Root cause • Solve problems permanently
• Team approach
• Line and specialist responsibility
• Continual education
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JIT Implementation Requirements: Measure Performance
• Emphasize improvement
• Track trends
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JIT in Services (Examples)
• Organize Problem-Solving Groups
• Upgrade Housekeeping
• Upgrade Quality
• Clarify Process Flows
• Revise Equipment and Process Technologies
©The McGraw-Hill Companies, Inc., 2004
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JIT in Services (Examples)
• Level the Facility Load
• Eliminate Unnecessary Activities
• Reorganize Physical Configuration
• Introduce Demand-Pull Scheduling
• Develop Supplier Networks
©The McGraw-Hill Companies, Inc., 2004
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Question BowlJust-In-Time seeks to achieve high volume
production using what three approaches: (5 points each item)
a. Minimal inventory of r-- m--------
b. Minimal inventory of w--- i- p------
c. Minimal inventory of f------- g----
Answer: raw materials, work in process, finished goods.
©The McGraw-Hill Companies, Inc., 2004
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Question BowlLean Management is closely associated
with which of the following? (5 points)
a. Big JIT
b. Little JIT
c. Honda Motor Company
d. McDonald’s low carb menu item
e. The Atkins Diet
Answer: a. Big JIT
©The McGraw-Hill Companies, Inc., 2004
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Question BowlIn the Toyota Production System, the
“elimination of waste” involves: (5 points for each item):
1. O-------------
a. W------ T---
b. T-------------
Answer: overproduction, wasting time, transportation
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Question BowlIn the JIT Pull System the partner that
begins the process of “pulling” is which of the following? (5 points)
a. Customers
b. Vendors
c. Fabrication personnel
d. CEO
e. All of the aboveAnswer: a. Customer
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Question BowlA JIT Production program requires: (5
points each item)
1. E------- P-----------
a. T----- Q------ C------
b. S----- l– s----
c. C--------- i----------
Answer: Employee participation, Total Quality Control, Small lot sizes, continuous improvement
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Question BowlInventory has been known to hide the
following production problems? (5 points each item)
a. S----
b. V----- d------------
c. D------- b--------
Answer: Scrap, Vendor delinquencies, decision backlogs
©The McGraw-Hill Companies, Inc., 2004
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Question BowlYou want to determine how many kanban card sets you
need for an operation. You find that average number of units demanded is 1,000 per hour, the lead time to replenish the order for this item is 10 hours, the container size is 10 units, and the safety stock is estimated to be 5% of the expected demand. Which of the following is the desired number of kanban card sets? (15 points)
a. 1050
b. 1000
c. 605
d. 500
e. None of the above
Answer: a. 1050 ([1000x10](1+0.05)/10=1050)
©The McGraw-Hill Companies, Inc., 2004
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Question BowlWhen trying to implement JIT a “stabilized
schedule” includes which of the following? (5 points)
a. Demand pull
b. Backflush
c. Fail-safe methods
d. All of the above
e. None of the above
Answer: e. None of the above (These include: level schedule, underutilization capacity, and establish freeze windows.)