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Pull Manufacturing and Just In Time. Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time

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pull manufacturing and just in time

Pull Manufacturing and Just In Time

Superfactory Manufacturing Excellence Series

Lean Overview

5S & Visual Factory

Cellular Manufacturing

Jidoka

Kaizen

Poka Yoke & Mistake Proofing

Quick Changeover & SMED

Production Preparation Process (3P)

Pull Manufacturing & Just In Time

Standard Work

Theory of Constraints

Total Productive Maintenance

Training Within Industry (TWI)

Value Streams

contents
Contents
  • Introduction
  • Background and History
  • Components and Implementation
  • Knowledge Check

© 2007 Superfactory™. All Rights Reserved.

introduction
Introduction
  • Just In Time (JIT) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and cycle time. The process is driven by a series of signals, or Kanban, that tell production processes to make the next part. When implemented correctly, JIT can lead to dramatic improvements in a manufacturing organization's return on investment, quality, and efficiency.

© 2007 Superfactory™. All Rights Reserved.

components and implementation
Components and Implementation
  • Pull vs. Push Scheduling
  • The Problem of Inventory
  • Just In Time
    • Principles
    • Benefits and Limitations
  • Implementing JIT
    • Kanban
    • Pull Systems
    • Quality
    • One Piece Flow
    • Continuous Flow
    • Takt Time
  • JIT and Suppliers

© 2007 Superfactory™. All Rights Reserved.

push vs pull scheduling
Push Vs. Pull Scheduling
  • Push Scheduling
  • traditional approach
  • “move the job on when finished”
  • problems - creates excessive inventory
  • Pull scheduling
  • coordinated production
  • driven by demand (pulled through system)
  • extensive use of visual triggers
  • (production/withdrawal kanbans)

© 2007 Superfactory™. All Rights Reserved.

inventory hides problems
Inventory Hides Problems

Work in process inventory level(hides problems)

Unreliable Vendors

Capacity Imbalances

Scrap

© 2007 Superfactory™. All Rights Reserved.

the philosophy of jit
The Philosophy of JIT
  • JIT means getting the right quantity of goods at the right place and the right time
  • Often termed “Lean Systems”
  • All waste must be eliminated- non value items
  • Broad view that entire organization must focus on serving customers
  • JIT is built on simplicity- the simpler the better
  • Focuses on improving every operation- Kaizen
  • Install simple visible control systems
  • Flexibility to produce different models/features

© 2007 Superfactory™. All Rights Reserved.

elements of jit manufacturing
Elements of JIT Manufacturing
  • JIT Manufacturing is a philosophy of value-added manufacturing
  • Achieved by
  • Inventory reduction - exposes problems
  • Kanbans & pull production systems
  • Small lots & quick setups
  • Uniform plant loading
  • Flexible resources
  • Efficient facility layouts

© 2007 Superfactory™. All Rights Reserved.

jit tactics
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

© 2007 Superfactory™. All Rights Reserved.

jit and suppliers
JIT and Suppliers
  • Few
  • Nearby (if possible)
  • Repeat business/Longer Term Agreements
  • Analysis to enable desirable suppliers to become or stay price competitive
  • JIT Logistics:
    • Frequent Deliveries/Smaller Quantities
    • Exact Quantities
    • Consumption initiates deliveries
    • Deliveries directly to the point of use
  • Perfect Parts
  • Concurrent engineering design practices

© 2007 Superfactory™. All Rights Reserved.