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Just-In-Time and Lean Production

JIT: Definitions? . JIT Head Chicken JIT Oh JIT (O

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Just-In-Time and Lean Production

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    1. Chapter 11 Just-In-Time and Lean Production

    2. JIT: Definitions? JIT Head Chicken JIT Oh JIT (O´JIT) Tough JIT Strate JITs

    3. What is JIT ?

    4. What is JIT? a corporate system designed to produce output within the minimum lead time and at the lowest total cost by continuously identifying and eliminating all forms of corporate waste and variance. a corporate strategy a philosophy Focus of JIT: • variance & waste

    5. Seven Basic Types of Waste Waste from overproduction Waste from waiting times Transportation waste Process Waste Inventory Waste Waste of motion Waste from product defects

    6. Waste in Operations

    7. Waste in Operations

    8. Waste in Operations

    9. Common Causes of Waste Layout (distance) Long setup time Incapable processes Poor maintenance Poor work methods Lack of training

    10. Objectives of JIT Produce only the products the customer wants. Produce products only at the rate that the customer wants them. Produce with perfect quality Produce with minimum lead time. Produce products with only those features the customer wants. Produce with no waste of labor, material or equipment -- every movement must have a purpose so that there is zero idle inventory. Produce with methods that allow for the development of people

    11. Basic Elements of JIT

    12. Flexible Resources

    13. Standard Operating Routine for a Worker

    14. Cellular Layouts

    15. Manufacturing Cell with Worker Routes

    16. Worker Routes Lengthened as Volume Decreases

    17. JIT Principles Create flow production • one piece flow • machines in order of processes • small and inexpensive equipment • U cell layout, counter clockwise • multi-process handling workers • easy moving/standing operations • standard operations defined

    18. Balanced Production • TAKT time • Objective -- Build at rate that the customer wants work • Balance the system to maximize efficiency at this rate

    19. TAKT Time TAKT • the beat • (Net Available Operating Time) / Customer Requirements • time periods must be consistent Example of calculation

    20. TAKT Time Example Net Available Operating Time • Time per shift 480´ • Breaks (2 @ 10´) - 20´ • Clean-up - 20 • Lunch - 30 • NAOT/shift 410´ Customer Requirements • Monthly 26,000 • No. Working Days 20 • CR/Day 1,300 T/T • 410´/shift*60"/min*3 shifts/1,300 • 56.769" per part or 57"

    21. The Pull System

    22. Kanban Production Control System

    23. A Sample Kanban

    24. The Origin of Kanban

    25. Types of Kanbans

    26. Types of Kanbans

    27. Types of Kanbans

    28. Types of Kanbans

    29. Determining Number of Kanbans

    30. Determining the Number of Kanbans

    31. Small-Lot Production

    32. Inventory Hides Problems

    33. Lower Levels of Inventory Expose Problems

    34. Components of Lead Time

    35. SMED Principles

    36. Common Techniques for Reducing Setup Time

    37. Common Techniques for Reducing Setup Time

    38. Common Techniques for Reducing Setup Time

    39. Uniform Production

    40. Mixed-Model Sequencing

    41. Quality at the Source

    42. Visual Control

    43. Visual Control

    44. Visual Control

    45. Kaizen

    46. Total Productive Maintenance (TPM)

    47. TPM Requires Management to:

    48. Supplier Policies

    49. Benefits of JIT

    50. JIT Implementation

    51. JIT In Services

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