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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

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Pull Manufacturing and Just In Time

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  1. 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

  2. Contents • Introduction • Background and History • Components and Implementation • Knowledge Check © 2007 Superfactory™. All Rights Reserved.

  3. 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.

  4. 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.

  5. 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.

  6. Inventory Hides Problems Work in process inventory level(hides problems) Unreliable Vendors Capacity Imbalances Scrap © 2007 Superfactory™. All Rights Reserved.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

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