CHAPTER 8-JIT & Lean Manufacturing #

8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #

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PRODUCTIONPLANNING AND

CONTROL(MEFB 433)

Dr. Weria Khaksar

Email: [email protected]

Room No. BN-03-08



8- JIT & LEANMANUFACTURING



Manufa!u"#n$Lean O%e"a!#n' A e#*+e ,,!e. !/a! u,e,

.#n#.a+ "e,u"e, and %"due, /#$/ 0ua+#!$d, " ,e"1#e,2

ean systems are sometimes re!erred to as Ju,!-#n-!#.e (JIT) systems owin" to their hi"hly #oordinated

a#ti$ities and deli$ery o! "oods that o##ur %ust asthey are needed.

Ju,!-#n-!#.e (JIT)' A /#$/+ "d#na!ed%"e,,#n$ ,,!e. #n /#/ $d, .1e

!/"u$/ !/e ,,!e. and ,e"1#e, a"e%e"f".ed 5u,! a, !/e a"e needed2

ean manu!a#turin" was de$elo&ed 'y the (a&aneseautomo'ile manu!a#turer )oyota.

An!/e" ea.%+e' the *eneral +otors ,*+ /812and N++4 ,New nited +otor +anu!a#turin"5 4n#.



Manufa!u"#n$T/e T!a A%%"a/'

Muda' Waste and ine7#ien#y. )he dri$in"&hiloso&hy.6an*an' manual system that si"nals theneed !or &arts or materials.

Pu++ 7,!e.' Re&la#in" material or &arts 'asedon demand9 &rodu#e only what is needed.e#5un9a' ariations in &rodu#tion $olume leadto waste.

6a#:en' ;ontinuous im&ro$ement o! thesystem.

J#d9a' <uality at the sour#e. Ea#h worker ise=&e#ted to &er!orm on"oin" >uality assuran#e.

P9a-9e' ?a!e"uards 'uilt into a &ro#ess to



Manufa!u"#n$T/e $a+, and *u#+d#n$ *+9, f +ean

,,!e.,'

Disru&tions ha$ea ne"ati$einuen#e on thesystem 'yu&settin" thesmooth ow o!

&rodu#ts throu"hthe system5 andthey should 'eeliminated.Disru&tions are

#aused 'y &oor>uality5e>ui&ment'reakdowns5#han"es to the

s#hedule5 and

Waste re&resentsun&rodu#ti$e

resour#es andeliminatin" waste#an !ree u&resour#es andenhan#e

&rodu#tion. )here are se$enwastes in the lean&hiloso&hy:/. 4n$entory

1. A$er&rodu#tion3. Waitin" time. nne#essary

trans&ortin"6. Cro#essin"

waste

. 4ne7#ient work

e=i'lesystem is onethat is ro'ustenou"h tohandle a mi= o!

&rodu#ts5 o!tenon a daily 'asis5and to handle#han"es in the

le$el o! out&utwhile stillmaintain'alan#e ands&eed.



Manufa!u"#n$

BUILDING BLOC67' P"du! De,#$n

•

7!anda"d %a"!,' the workers ha$e !ewer&arts to deal with5 and trainin" times and#osts are redu#ed. Cur#hasin"5 handlin"5and #he#kin" are more routine and lendthemsel$es to #ontinual im&ro$ement. )he

&ro#esses #an 'e standardiFed.• Mdu+a" De,#$n' an e=tension o! standard

&arts. +odules are #lusters o! &arts treatedas a sin"le unit.

•;ua+#!' <uality is the sine >ua non o! lean.4t is #ru#ial to lean 'e#ause &oor >uality #an#reate ma%or disru&tions.

• Cnu""en! En$#nee"#n$' En"ineerin"#han"es #an 'e $ery disru&ti$e to smootho&erations. ;on#urrent en"ineerin"



Manufa!u"#n$

BUILDING BLOC67' P"e,, De,#$n

• 7.a++ L! 7#:e,' 4n lean &hiloso&hy5 theideal lot siFe is one unit5 a >uantity that maynot always 'e realisti#. BeneGts:

• 7e!u% T#.e Redu!#n' ?mall lots and#han"in" &rodu#t mi=es re>uire !re>uentsetu&s.



Manufa!u"#n$


• Manufa!u"#n$ Ce++,'

•

;ua+#! I.%"1e.en!'

• P"du!#n F+e#*#+#!'



Manufa!u"#n$


•A Ba+aned 7,!e.'



Manufa!u"#n$


•L#!!+e In1en!" 7!"a$e'



Manufa!u"#n$


•Fa#+-7afe Me!/d,'



Manufa!u"#n$

BUILDING BLOC67'

Pe",nne+<O"$an#:a!#na+ E+e.en!,

• ="9e", a, a,,e!,'

• C",,-!"a#ned "9e",'



Manufa!u"#n$

BUILDING BLOC67'

Pe",nne+<O"$an#:a!#na+ E+e.en!,• Cn!#nuu, #.%"1e.en!'



Manufa!u"#n$

BUILDING BLOC67'

Pe",nne+<O"$an#:a!#na+ E+e.en!,• C,! aun!#n$'



Manufa!u"#n$

BUILDING BLOC67'

Pe",nne+<O"$an#:a!#na+ E+e.en!,• Leade",/#%<%"5e! .ana$e.en!'



Manufa!u"#n$

BUILDING BLOC67' Manufa!u"#n$ P+ann#n$ and

Cn!"+• Le1e+ +ad#n$'



Manufa!u"#n$

BUILDING BLOC67' Manufa!u"#n$

P+ann#n$ and Cn!"+• Pu++ ,,!e.,'



Manufa!u"#n$

BUILDING BLOC67' Manufa!u"#n$P+ann#n$ and Cn!"+

• >#,ua+ ,,!e.,'



Manufa!u"#n$


• L#.#!ed "9-#n-%"e,, (=IP)'





Manufa!u"#n$


• Redued !"an,a!#n %"e,,#n$'



Manufa!u"#n$


• P"e1en!#1e .a#n!enane and/u,e9ee%#n$'



Manufa!u"#n$

JIT II' 4n some instan#es5 #om&aniesallow suppliers to mana"eresto#kin" o! in$entory o'tained!rom the su&&liers. su&&lier

re&resentati$e works ri"ht in the#om&anyHs &lant5 makin" sure thereis an a&&ro&riate su&&ly on hand.

)he term JIT II is used to re!er tothis &ra#ti#e. (4) 44 was &o&ulariFed'y the Bose ;or&oration. 4t is o!ten

re!erred to as vendor-managed

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CHAPTER 8-JIT & Lean Manufacturing #