1 / 14

Week 14A – Lean Systems (Chapter 16)

Week 14A – Lean Systems (Chapter 16). Production Environments; Lean Operations (“JIT”) History, Goals and Building Blocks; Maintenance. Production Environments. Product Characteristics (continuum) Customized <--------------> Commodity Operation Types (continuum) Project ¯|¯

Download Presentation

Week 14A – Lean Systems (Chapter 16)

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Week 14A – Lean Systems(Chapter 16) Production Environments; Lean Operations (“JIT”) History, Goals and Building Blocks; Maintenance SJSU Bus 140 - David Bentley

  2. Production Environments • Product Characteristics (continuum) • Customized <--------------> Commodity • Operation Types (continuum) • Project ¯|¯ • Batch or Job | • Repetitive/Assembly | • Continuous flow _|_ SJSU Bus 140 - David Bentley

  3. History of Lean Operations (“JIT”) • Japanese Post-WW II conditions • Emphasis on quality and eliminating waste • Also called “lean manufacturing” or the “Toyota production system” • U.S. attention as a result of oil embargo • Change in philosophy needed in U.S. • Also called “Zero Inventory” in U.S. SJSU Bus 140 - David Bentley

  4. Obstacles to “JIT” in the US • Emphasis on MRP systems • Fit job shops most closely • APICS, Oliver Wight and others • Cost Accounting • Traditional job accounting • Management • Reluctance to empower employees • Focus on high utilization • Limited allowance for training SJSU Bus 140 - David Bentley

  5. Key Contributors to “JIT” - 1 • Japan (developer) • TaichiOhno (Toyota Motor Company) • Toyota Production System • Aka Lean Production or Lean Manufacturing SJSU Bus 140 - David Bentley

  6. Key Contributors to “JIT” - 2 • US (popularizers) • RichardSchonberger (U of Nebraska, U of Washington) • Emphasized concepts, management aspect • “Japanese Manufacturing Techniques” • “World Class Manufacturing” • RobertHall (U of Indiana) • Emphasized specific tools and techniques • “Zero Inventories” SJSU Bus 140 - David Bentley

  7. Lean Operations Goals • Eliminate waste • Smooth the flow • Minimize disruptions • Minimize inventory • Reduce queue, setup, wait, transit times • Reduce lead time • Introduce flexibility • Reduce cost SJSU Bus 140 - David Bentley

  8. Lean Operations Requirements • Management commitment • Quality • Training • Worker involvement / ownership • Flexibility - people and equipment • Process changes • Supplier partnerships SJSU Bus 140 - David Bentley

  9. Building Blocks - 1 • Product design • Standard parts • Modular design • Capable production systems SJSU Bus 140 - David Bentley

  10. Building Blocks - 2 • Process design • Quality improvement • Small lot sizes • Setup time reduction • Manufacturing cells • Limited WIP • Production flexibility • Minimal inventory storage SJSU Bus 140 - David Bentley

  11. Building Blocks - 3 • People • View employees as assets • Cross-training • Commitment to continuous improvement • Cost accounting (big obstacle in U.S. due to job costing bias) • Leadership SJSU Bus 140 - David Bentley

  12. Building Blocks - 4 • Manufacturing planning and control • Level loading • Pull systems • Visual signals (Kanban) • Container, card(s), cart, taped space on floor or counter, colored lights (??), golf balls (??) • Supplier partnerships • Reduced transaction processing • Preventive maintenance and housekeeping SJSU Bus 140 - David Bentley

  13. Making the change • Insure true management commitment • Provide employees training • Focus on internal operations before moving on to suppliers • Start small (one line) and at end of process • Deal with cost accounting issues early • Now extend to your suppliers SJSU Bus 140 - David Bentley

  14. Determining the Number of Kanban Containers • Number of containers = DLT + SS ------------ Container size • Example: Demand = 400 per day; Lead Time = 2 days; Safety stock = 100; container size = 90 Number of containers = (400)(2) + 100 ---------------- = 10 90 SJSU Bus 140 - David Bentley

More Related