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1. Vi-Jon Laboratories Vi-Jon Laborites

2. Vi-Jon Laboratories continuous flow of inventory with the ability to stop and start with demand. Demand is high inventory Flows through the plant on a continuous bases. Vi-Jon Laborites

3. As production needs slow and demand is met the inflow of inventory subsides. Large amounts of inventory are not held at the plant, safety buffers are in place so that production can start when demand rises again. Vi-Jon Laborites

6. SYNCHRONIZED MANUFACTURING THE DRUM-BUFFER-ROPE-WAY ORDERS ASSEMBLY MANUFACTURING OPERATIONS OPERATIONS DONE BY C.C.R. TIME BUFFERS ROPES IN ANY PLANT THERE ARE VERY FEW CAPACITY CONSTRAINT RESOURCES.

8. SYNCHRONIZED MANUFACTURING BEATING THE DRUM Ensure maximum throughput through forward scheduling of the C.C.R.’S Due dates give us the first, rough sequence, but the sequence must be modified under any one of four conditions….

16. SYNCHRONIZED MANUFACTURING BUFFER MANAGEMENT Case 1 Case 2 CASE 3

17. SYNCHRONIZED MANUFACTURING FOCUSING IMPROVEMENTS Discrepancy between planned and actual buffers reveals the disruptions to material flow. Y HOURS Hours of CCR W A hole representing Y hours of Part A inventory scheduled To be worked on in W hours are missing. This information can be used to quantify the disruption.

18. SYNCHRONIZED MANUFACTURING FOCUSING IMPROVEMENTS Trace location of inventory missing from buffer This will help identify the source of disruption P,W and Y can be used to quantify the magnitude of the disruption Buffer Y HOURS W P The processing time still left to complete the parts Disruptive source Inventory location

22. SYNCHRONIZED MANUFACTURING FOCUSING IMPROVEMENTS Throughput Increases Less excess capacity to cope with disruptions Buffer Increases The need to continue to reduce the buffer Bottlenecks that limit increased production Inexpensive alternatives to buying more machines Capacity increase Net Return ON Cash Profit Investment Flow

23. THE COMPETETIVE EDGE RACE PRODUCTIVITY FLYWHEEL SYNCHRONIZED MANUFACTURING NP ROI CF BUFFER MANAGEMENT LOCAL PROCESS IMPROVEMENTS JIT TECHNOLOGY MANAGEMENT

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