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Lean Systems

Lean Systems. Pull method of materials flow Consistently high quality Small lot sizes Uniform workstation loads Standardized components and work methods Close supplier ties Flexible workforce Line flows Automated production Preventive maintenance.

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Lean Systems

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  1. Lean Systems

  2. Pull method of materials flow • Consistently high quality • Small lot sizes • Uniform workstation loads • Standardized components and work methods • Close supplier ties • Flexible workforce • Line flows • Automated production • Preventive maintenance Characteristics of Lean Systems: Just-in-Time

  3. Lot Size and Cycle Inventory

  4. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  5. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  6. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory Lot size = 50 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  7. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory Lot size = 50 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  8. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory Lot size = 50 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  9. Unreliable suppliers Capacity imbalance Scrap Continuous Improvement with Lean Systems Figure 16.2

  10. Single-Card Kanban System

  11. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  12. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  13. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  14. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  15. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  16. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  17. Assembly line 1 Assembly line 2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers O2 Fabrication cell O3 O1 Full containers O2 Figure 16.3

  18. Each container must have a card • Assembly always withdraws from fabrication (pull system) • Containers cannot be moved without a kanban • Containers should contain the same number of parts • Only good parts are passed along • Production should not exceed authorization Part Number: 1234567Z Location: Aisle 5 Bin 47 Lot Quantity: 6 Supplier: WS 83 Customer: WS 116 Single-Card Kanban System KANBAN

  19. Number of Containers

  20. d( w + p )( 1 + a ) c k = d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers Example 16.1

  21. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers 2000( 0.08 + 0.02 )( 1 + 0.10 ) 22 k = Example 16.1

  22. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers 2000( 0.08 + 0.02 )( 1 + 0.10 ) 22 k = Example 16.1

  23. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers Example 16.1

  24. d( w + p )( 1 + a ) c k = d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers Example 16.1

  25. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers 2000(0.06 + 0.02)(1.10) 22 k = Example 16.1

  26. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers 2000(0.06 + 0.02)(1.10) 22 k = Example 16.1

  27. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers k = 8 containers Example 16.1

  28. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units k = 10 containers k = 8 containers Figure 16.4 Westerville Auto Parts Number of Containers

  29. Consistently high quality • Uniform facility loads • Standardized work methods • Close supplier ties • Flexible workforce • Automation • Preventive maintenance • Pull method of materials flow • Line flows Lean Systems in Services

  30. Reduce space requirements • Reduce inventory investment • Reduce lead times • Increase labor productivity • Increase equipment utilization • Reduce paperwork and simple planning systems • Valid priorities for scheduling • Workforce participation • Increase product quality Operational Benefits

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