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Jit systems

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Transcript

  • 1. JIT SYSTEMS
  • 2.
    • Japanese industry works JUST IN TIME
    • Others work JUST IN CASE
    STOCKLESS PRODUCTION ? JIT System is the organisation of resources, information flows and decision rules that can enable an organisation to realise the benefits of JIT philosophy
  • 3. Push & Pull
    • When to use?
    • Is JIT applicable in all manufacturing environments ?
    Highly repetitive Well defined Material Flows Deterministic Pull Systems : Is it Made to order? Is there a delay at Customer delivery end?
  • 4. MURI MURA MUDA EXCESS WASTE UNEVENNESS X X X From Overproduction Waiting Time Transportation Inventory Processing Waste Waste of motion Product defects
  • 5. Characteristics
    • Consistently High quality : Low rework
    • How to achieve ?
    • andon systems?
  • 6. (SINS) OF MANUFACTURING
    • EOQ ?
    • SET UP TIME ?
    • ECONOMIES OF SCALE ?
    • SQC?
    • THE SECURITY BLANKET?
  • 7. Setup, Capacity and JIT
    • JIT has low leadtime (MLT)
    • Higher capacity can reduce MLT?
      • Example :
        • Arrival rate of products : 15/hour
        • Service rate : 16 /hour
        • Lead time ?
  • 8. Setup, Capacity and JIT
    • JIT has low leadtime (MLT)
    • Higher capacity can reduce MLT?
      • Example :
        • Arrival rate of products : 15/hour
        • Service rate : 15.1 /hour
        • Lead time = 1/(mu-lambda) = 1/0.1 = 10 hours
        • If service rate changes by 1.3%
        • Lead time reduces to 3.33 hours
        • A small increase in production rate A LARGE SAVING IN MLT
        • What about inventory?
  • 9. Setup, Capacity and JIT
    • Finding the inventory reduction?
      • Example :
        • Arrival rate of products : 15/hour
        • Service rate : 15.1 /hour
        • WIP (no.of units in system) = lambda/(mu-lambda) = 15/0.1 = 150 units
        • If service rate changes by 1.3%
        • WIP reduces to 15/0.3 i.e. 50 units
        • A small increase in production rate A LARGE SAVING IN Inventory
      • HOW TO ACHIEVE?
        • Set up
        • Capacity
  • 10. (SINS) OF JIT ?
    • A GLORIFIED INVENTORY MGMT?
    • EXPENSIVE
    • WHY SHOULD SUPPLIER CARRY THE BURDEN?
    • JIT NEEDS HARDWORK... WHY SHOULD I DO IT?
  • 11. SNOW BALL EFFECT jit Reduced stock quality Overhead costs Setup time scrap problems Feedback Cost Savings Even Production Process
  • 12. Characteristics
    • Pull System for Material Flow
    • Consistently High Quality
      • Control of quality at source
      • Use of SQC techniques
    • Lot Sizes
      • WIP inventory
      • Uniform load at workstations
      • Single digit setup
  • 13. Characteristics: Consistent Quality
    • Can you reduce defect rate by increasing lot size?
    • Small Lot size?
    Reduce cycle inventory Reduce lead times - why? Uniform operating system load But what about setup time?
  • 14. Characteristics
    • Uniform workstation load
      • Mixed model assembly (Heijunka)
    • Standardized components and work methods
      • The learning curve of repeated tasks
    • supplier ties
      • Lean base, short lead time, VMI
      • Local base
      • “ Complete Tear down” philosophy
  • 15. Characteristics
    • Flexible work force
      • Team Approach in Volvo
    • Line flow Strategy :
      • GT Layout
      • One Worker Multiple Machines
    • Automated Production - always ?
    • Preventive and Productive Maintenance