37020766 jit-and-lean-manufacturing-by-sashi-prabhu

Just-In-Time and Lean Manufacturing by Sashi Prabhu

Definition of JIT: ,[object Object]

Definition of JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

JIT Synonyms ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Definition of Lean Manufacturing ,[object Object],[object Object],[object Object],[object Object]

Time-Based Competition ,[object Object],[object Object],[object Object],[object Object]

Order-to-Delivery Cycle Distri- bution and Customer Service Custo- mer Places Order Order Entry Engi- neering Design If reqd. Sched- uling Manufacturing Lead Times Purchasing Lead Times Manufacturing Cumulative Lead Time Order-to-Delivery Cycle

Traditional View of Manufacturing ,[object Object],[object Object],[object Object],[object Object]

JIT Manufacturing Philosophy ,[object Object],[object Object],[object Object],[object Object]

Capacity Utilization 10 20 30 40 50 60 70 80 90 100 5 1 3 % Capacity Utilization 11 Production Lead Times (days) 7 9 Traditional Manufacturing JIT Manufacturing

Increasing Production Capacity Reduces Manufacturing Lead Times ,[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],Necessary Production Capacity

Work-in-Process Inventory ,[object Object]

Example: Necessary Production Capacity ,[object Object],[object Object],[object Object]

Example: Necessary Production Capacity ,[object Object],[object Object],[object Object],[object Object]

Example: Reduction in WIP ,[object Object],[object Object]

Example: Reduction in WIP ,[object Object],[object Object],[object Object],[object Object]

Successful JIT Applications ,[object Object],[object Object],[object Object]

Changes Required for JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Elements of JIT Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Eliminating Waste in Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Problem Solving and Continuous Improvement ,[object Object],[object Object],[object Object],[object Object],[object Object]

Uncovering Production Problems Water level must be lowered! Quality Problems Material Shortages Machine Breakdowns Workload Imbalances Worker Absenteeism Out-of-Spec Materials Quality Problems In-Process Inventory Production Problems

People Make JIT Work ,[object Object],[object Object],[object Object],[object Object]

TQM and JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Parallel Processing ,[object Object],Op 1 Op 2 Op 3 Op 4 Op 5 Op 6 Op 7 Op 8 ,[object Object],Cycle Time for Each Operation = 1 Hour Total Product Cycle Time = 1 x 5 = 5 Hours ,[object Object],[object Object],Cycle Time for Each Operation = 1 Hour Total Product Cycle Time = 1 x 8 = 8 Hours Op 1 Op 2 Op 3 Op 4 Op 5 Op 6 Op 7 Op 8

JIT: A Pull System ,[object Object],[object Object],[object Object]

Kanban Production Control ,[object Object],[object Object],[object Object]

Kanbans and Other Signals ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Kanban Cards Conveyance Kanban Card Part number to produce: M471-36 Part description: Valve Housing Lot size needed: 40 Container type: RED Crate Card number: 2 of 5 Retrieval storage location: NW53D From work center: 22 To work center: 35

Kanban Cards Production Kanban Card Part number to produce: M471-36 Part description: Valve Housing Lot size needed: 40 Container type: RED crate Card number: 4 of 5 Completed storage location: NW53D From work center: 22 To work center: 35 Materials required: Material no. 744B Storage location: NW48C Part no. B238-5 Storage location: NW47B

How Kanban Operates ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Flow of Kanban Cards and Containers Upstream Work Center #1 Downstream Work Center #2 In-process storage Parts Flow P-Kanban and empty container Full container and P-Kanban C-Kanban and empty container Full container and C-Kanban

Containers in a Kanban System ,[object Object],[object Object],[object Object],[object Object]

Calculating the No of Containers between Work Centers 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

Example: Number of Containers ,[object Object],[object Object],[object Object]

Example:Number of Containers ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Essential Elements of JIT Purchasing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

E-Commerce and JIT Purchasing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Reducing Inventories through Setup Time Reduction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Setup Time Required for an EOQ

[object Object],[object Object],Setup Time Required for an EOQ

Example: Setup Time Required ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Example: Setup Time Required ,[object Object]

Example: Setup Time Required ,[object Object],[object Object]

Working Toward Repetitive Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object]

Benefits of JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Wrap-Up ,[object Object],[object Object],[object Object],[object Object],[object Object]

37020766 jit-and-lean-manufacturing-by-sashi-prabhu

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