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Pull Manufacturing Kanban, Just in Time, Demand Flow

Pull Manufacturing Kanban, Just in Time, Demand Flow. Lean Manufacturing Series. Outline. Why Pull Manufacturing? The Problem of Inventory Just In Time Kanban One Piece Flow Demand / Pull Standard Work & Takt Time Production Smoothing. JIT Tactics.

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Pull Manufacturing Kanban, Just in Time, Demand Flow

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  1. Pull ManufacturingKanban, Just in Time, Demand Flow Lean Manufacturing Series

  2. Outline • Why Pull Manufacturing? • The Problem of Inventory • Just In Time • Kanban • One Piece Flow • Demand / Pull • Standard Work & Takt Time • Production Smoothing

  3. JIT Tactics • Single Minute Exchange of Dies (SMED) • Statistical Process Control • Use of standard containers • Doable stable schedules with adequate visibility • TAKT-Time • 5-S Program • Kaizen Event • Visual control • Flexible workers • Tools at the point of need • Product redesign • Group Technology • Total Productive Maintenance

  4. Kanban Production Control Systems Production Kanban Withdrawal Kanban A Machine Center Assembly Line B Storage ....

  5. TAKT Time Example • Net Available Operating Time • Time per shift 480´ (minutes) • Breaks (2 @ 10´) - 20´ • Clean-up - 20’ • Lunch - 30’ • NAOT/shift 410´ • Customer Requirements • Monthly 26,000 units/month • No. Working Days 20 days/month • CR/Day 1,300 units/day • TAKT Time • 410’ x 60” x 3 shifts (73,800) divided by 1,300 • 57.769 seconds per part or 57"

  6. Production Smoothing / Leveling • Averaging both the volume and the production sequence of different model types on a mixed-model production line • Example: Toyota Manufacturing • Toyota makes 3 car models - a convertible, hardtop, and an SUV. Assume that customers are buying nine convertibles, nine hardtops, and nine SUVs each day. What is the most-efficient way to make those cars?

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