09_just in time manufacturing.pdf

7/29/2019 09_Just In Time Manufacturing.pdf

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Johan Oscar Ong, ST, MT


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Elimination of all waste and continuous

improvement of productivity

ADDING VALUE

the customer wants, does it well and

consistently, and is available when the customer

want it

Another word for this is quality


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Waste caused by poor product specification

and design Component standardization

The process

Methods (searching, walking, etc)

Movement

Product defects Waiting time

Overproduction

Inventory


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Introduced by Shigeo Singo of Japan

SQC does not prevent defectsHe differentiated between errors and defects Errors will always be made, but defects can be

Corrective action should take place immediatelyafter a mistake is made

Successive check inspection (the next person inthe process who passes the information back tothe worker who just performed the operation)

Self check

Source inspection (checks for error that willcause defects)


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PY tries to change either the process or its

resources thus eliminating the need to relyon human experience and knowledge

Examples:

Use color-coded parts Put a template over an assembled

component to show operator where specific

parts goUse counters to tell an operator how many

operations have been performed


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Flow manufacturing or work cells

Work toward flexibility Process flexibility

Machine flexibility

Operator flexibility Quick changeover with short setup times


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High product and process quality

Six Sigma quality approach

Total productive maintenance

Uninterrupted flow of material with uniform

plant loading Continuous process improvement


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Work toward supplier partnering

Supplier selection Supplier certification

Three key factors Long-term commitment

Trust

Shared vision


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Forecasting and Production Planning not

significantly different

Master Production Scheduling focus on level

and stable schedules

MRP can be used to plan for supplier parts

and for capacity


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A system that reacts to usage and pulls

replacement material Contrast MRP uses push

Limits inventory by having very small lots

Low cost because of setup reductions

One common approach the Kanban system


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With shortened lead times a constant goal in

JIT, a system is needed to generate thereorder point signal without having to rely on

a formal structured system that could take

Kanban signal identifies the material to

which it is attached

Component part number and id

Storage location

Container size

Work center of origin


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Make presentation to explain the kanban

system !With example from book


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Value Stream Mapping Process flow

analysis focusing on reduction of non-value added activities

Kaizen Structured approach to

5S approach Focus on orderliness andcleanliness

09_just in time manufacturing.pdf

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