Just-in-Time and Lean Systems Just-in-Time and Lean Systems.
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Transcript of Just-in-Time and Lean Systems Just-in-Time and Lean Systems.
Abid Haleem, JMI 2
The Philosophy of JIT 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
Abid Haleem, JMI 3
A Simple Definition of JIT
A philosophy of manufacturing based on planned elimination of ALL waste,
and improvement of productivity and customer value,
through “Continuous Improvement” (or ‘Kaizen’) ……
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Waste is ‘anything other than the minimum amount of equipment, materials, parts, space, and worker’s time, which are absolutely essential to add value to the product.’
— Shoichiro Toyoda President, Toyota © 1995 Corel Corp.
a. What is ‘Waste’?
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THE SEVEN WASTES
Waste of over productionWaste of over production Waste of waiting Waste of waiting Waste of transportation Waste of transportation Waste of processing itself Waste of processing itself Waste of stocks Waste of stocks Waste of motionWaste of motion Waste of making defective Waste of making defective
productsproducts
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The Problem of Manufacturing…
Getting the right material and physical resources together at the right place and at the right time to meet the customer’s requirements.
Desired features, On time delivery, High Quality, at the best price…
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Breaking down the problem… Getting the
material needed… Having enough
inventory of material to support production
Not having too much inventory and extra costs…
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Claims for JIT: reduced inventoryreduced inventory
shorter lead timesshorter lead times not too early, not to late...not too early, not to late...
JIT is the result businesses want, JIT is the result businesses want,
not a starting pointnot a starting point
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A More Complete Definition of JIT
JIT (Just-In-Time)is
a STATE OF MINDfor
achieving competitive excellenceby
creating an attitude of continuous improvement,
through 100 percent involvementto
eliminate all waste,institutionalizing only value-adding
activitieswith
100 percent quality—NOTHING LESS
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Elements of JIT Manufacturing
Inventory reduction exposes problems
Kanbans & pull production systems Small lots & quick setups Uniform plant loading Flexible resources Efficient facility layouts
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Role of Inventory Reduction Inventory = Lead Time (less is better) Inventory hides problems
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Small Lot Sizes & Quick Setups
Small lots mean less average inventory and shorten manufacturing lead time
Small lots with shorter setup times increase flexibility to respond to demand changes
Strive for single digit setups- < 10 minutes
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Effective Facility Layouts Workstations in close physical proximity
to reduce transport & movement Streamlined flow of material Often use:
Cellular Manufacturing (instead of process focus)
U-shaped lines: (allows material handler to quickly drop off materials & pick up finished work)
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Traditional Process Focused Layout
Jumbled flows, long cycles, difficult to schedule
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Process Layout Characteristics Advantages
Deep knowledge of the process Common tooling and fixtures Most Flexible -- can produce many different
part types Disadvantages
Spaghetti flow -- everything gets all tangled up (can not “pull” materials with this layout)
Lots of in-process materials Hard to control inter-department activities Can be difficult to automate
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PRODUCT LAYOUT
Shipping
L L M D
L M D
G
L M GG
A A
Receiving
Part #1
Part #3
Part #2
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Product Layout Characteristics Advantages
Easy to control -- input control Minimum material handling -- frequently
linked to the next process Minimal in-process materials Can be more easily automated
Disadvantages Inflexible -- can only produce one or two parts Large setup Duplicate tooling is required for all cells
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JIT Cellular Manufacturing Product focused cells, flexible equipment,
high visibility, easy to schedule, short cycles
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Cellular Layout Characteristics Advantages
Control is simplified Common tooling and fixtures Flexible -- can produce many different part
types - a part family?? Disadvantages
Setup ?? Need to know about many different
processes
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Process Layout Work Cell
SawSaw
LatheLathe
GrinderGrinder
HeatHeatTreatTreat
LatheLathe
Lathe
Lathe SawSaw
HeatHeatTreatTreat
GrinderGrinder
GrinderGrinder
PressPress
PressPress 1
1
2
3
45
2
6
SawSaw
PressPress
From Process Layout to Work Cell – For Flow
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Benefits of JIT
Smaller inventories Shorter lead times Improved quality Reduced space requirements Lower production costs Increased productivity Greater flexibility
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Quality Processes Yield Quality Results
ConsistentProcess
DesiredResults
InconsistentProcess
InconsistentResults
Traditional = People doing whatever they can to get results
Lean = People using standard process to get results
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Definition of
Lean Manufacturing“A philosophy of production that emphasizes the minimization of the amount of all the resources (including time) used in the various activities of the enterprise. It involves:
… identifying and eliminating non-value-adding activities,
… employing teams of multi-skilled workers, … using highly flexible equipment, which
may eventually be automated.”
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Implementing JIT
Reorganize workplace Remove clutter & minimize storage
Reduce setup times Reduce lot sizes & lead times Implement layout changes
Cellular manufacturing & close proximity Switch to pull production Extend methods to suppliers
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People Make JIT Work JIT has a strong element of training and
involvement of workers. A culture of mutual trust and teamwork
must be developed. An attitude of loyalty to the team and
self-discipline must be developed. Another crucial element of JIT is
empowerment of workers, giving them the authority to solve production problems.
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Highlights JIT manufacturing has become the standard
for many industries; concept incorporates TQM and respect for people.
JIT views waste as anything that does not add value.
JIT converts traditional “push” systems to a “pull” production system.
Key elements of JIT are “pull”, kanbans, small lots, quick setups, uniform plant loading, flexibility, and work cells.
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Highlights (Continued)
TQM concepts must be incorporated JIT manufacturing.
Team based work systems, empowerment, cross-functional flexibility, with appropriate reward systems are all part of JIT.
Most of the JIT concepts are equally applicable to “Service Organizations.”
JIT requires changes to be made in all functional areas and examination of all processes for waste.