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Employability skills (a)

Employers value people who:

• fit well into their team and workplace

• use initiative to solve routine problems

• work productively

• have good time-management skills

• are committed to continuous learningand improvement.

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Employability skills (b)

Employability skills can:

• help you gain employment

• make you a productive and valuable worker

• increase your chances of promotion.

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Employability skills (c)

Employability skills developed inMSACMT221A Apply just-in-time (JIT) procedures:• Communication• Teamwork• Problem-solving• Self-management• Planning & organising• Technology• Lifelong learning• Initiative & enterprise

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Competitive (lean) manufacturing

To be competitive companies must:

• keep customers satisfied

• increase efficiency

• reduce costs

• reduce waste

• respond quickly

• continuously improve

• have enthusiastic and skilled staff.

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Seven types of waste in manufacturing

1. Overproduction

2. Defects

3. Inventory

4. Motion

5. Processing

6. Transportation

7. Waiting

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Lean manufacturing tools(Kaizens)

• 5S

• Pull systems (kanban)

• Value-stream mapping

• Just-in-time production

• Total productive maintenance

• Takt time

• Heijunka

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Lean manufacturing tools (Kaizens) cont …

• Jidoka

• Visual process control

• Error-proofing (poka-yoke)

• Waste (muda) elimination

• Cellular/flow production

• Set-up/changeover reduction

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What is just-in-time (JIT)?

JIT is a system that produces to order instead of producing to schedule.

 JIT gets what is needed:

• when it is needed

• in the quantity needed

• to the person who needs it

• in the shortest possible time.

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JIT terms

Takt time – the available production time divided by the customer-demanded quantity for a given period. Pull scheduling – producing only what customers want.  Push scheduling – the manufacturer decides when and how much of a product will be produced.  Kanban – signals customer demand; for example, cards, tickets, email.  Flow authorisation – a system that authorises the worker to make a product.

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Benefits of JIT

• Promotes efficiency and effectiveness through:

– smaller production lots

– faster turnaround times

– improved quality.

• Encourages quick changeovers.

• Increases employee involvement in problem solving and decision making.

• Lowers inventory.

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IntroductionPrepare for just-in-time

Just-in-time requires a great deal of preparation and discipline to achieve.

A number of prerequisites need to be in place before you can make the transition to JIT.

This introduction explains how to:

•Understand what customers perceive as value

•Identify the value stream

•Make improvements to the flow of products

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What the customer wants

• Quality – is it good enough?

• Cost – is it the right price?

• Delivery – can I get it when I need it?

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Process map symbols

Symbol Name Is value added?

Operation Yes

Transport No

Inspect No

Delay No

Storage No

Handle No

Decide No

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Process mapProcess mapping current state

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Process mapProcess mapping future state

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Value-stream map

Value-stream map (current state)

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Chapter 1Respond to indicators of demand

This chapter explains how to:

1.1 Identify pull of product through work role

1.2 Recognise indicator of flow authorisation

1.3 Identify production required

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Indicators of demand

• A work order

• A fax

• An empty container

• An empty space in an outbound stock point

• A ticket or card

• An email

• Verbal instructions

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Kanbans

A kanban signals customer demand.

Kanbans may be:

• cards

• work orders

• faxes or emails

• containers or locations.

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Chapter 2Make products to demand

This chapter explains how to:

2.1 Make product as required by ticket

2.2 Identify factors likely to prevent demand being satisfied

2.3 Take action in accordance with procedures

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What the indicator must tell you

• What needs to be made?

• How many of the items are needed?

• Who needs it?

• When it is needed?

• Where you need to deliver it?

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Production problems

• Man; for example, change in customer orders or staffing problems.

• Machine; for example, equipment failures.

• Method; for example, problems with production.

• Material; for example, problems with suppliers.

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Kanban rules

1. Only downstream operations can request production.

2. Only produce what is requested on the kanban.

3. Authorisation to produce is only made by cards or signals.

4. Each kanban card loops between pairs of workstations.

5. Only good parts are sent downstream.

6. Components are only manufactured in the order that the kanban card is received.

7. Be more efficient and gradually reduce the number of cards needed.

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Chapter 3Update demand information as required

Once the order has been fulfilled you must ensure:

• the order is delivered

• relevant paperwork and information is updated.

This chapter explains how to:

3.1 Record information on ticket to procedures

3.2 Facilitate operation of flow authorisation

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Chapter 4Recommend improvements

Once all of the elements are in place – customer, value stream, flow and pull – focus on applying

JIT to meet customer orders. This chapter explains how to:

4.1 Examine how the JIT system operates

4.2 Identify areas for improvement

4.3 Recommend improvements

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Continuous improvement

• Improvement is implemented across all areas of a company.

• The focus of improvement is on using knowledge, not spending a lot of money.

• Waste in any form should be identified and eliminated.

• Everyone is involved in the improvement process.

• Significant improvements are not made quickly or in large steps but in small increments.

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Visual management

Techniques include:

• visual display boards

• shadow boards

• visual control boards

• painted floors to identify work areas, storage areas, finished product areas etc.

• motivational statements

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Visual management cont …

• visual performance measurements

• standard work boards

• sign boards

• labels and colour-coding time savers

• pictorial procedures.

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Visual management cont …

Visual controls should be:

• focused

• simple

• easy to see and read

• not too busy

• colourful.

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Ways to recommend improvements

• Meetings

• Memos

• Project registers

• Brainstorming sessions

• Feedback systems

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