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sashi prabhu
sashi prabhu

The document discusses Just-In-Time (JIT) and Lean manufacturing philosophies. It defines JIT as eliminating waste and continuously improving productivity by having only required inventory, improving quality, reducing lead times, and revising operations at minimum cost. Lean manufacturing similarly aims to minimize all resources used. The document outlines key elements of JIT/Lean manufacturing like minimizing inventory, parallel processing, problem solving, and Kanban pull systems.

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Just-In-Time and Lean Manufacturing by Sashi Prabhu
Definition of JIT: ,[object Object]
Definition of JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
JIT Synonyms ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Definition of Lean Manufacturing ,[object Object],[object Object],[object Object],[object Object]
Time-Based Competition ,[object Object],[object Object],[object Object],[object Object]
Order-to-Delivery Cycle Distri- bution and Customer Service Custo- mer Places Order Order Entry Engi- neering Design If reqd. Sched- uling Manufacturing Lead Times Purchasing Lead Times Manufacturing Cumulative Lead Time Order-to-Delivery Cycle
Traditional View of Manufacturing ,[object Object],[object Object],[object Object],[object Object]
JIT Manufacturing Philosophy ,[object Object],[object Object],[object Object],[object Object]
Capacity Utilization 10 20 30 40 50 60 70 80 90 100 5 1 3 % Capacity Utilization 11 Production Lead Times (days) 7 9 Traditional Manufacturing JIT Manufacturing
Increasing Production Capacity Reduces Manufacturing Lead Times ,[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],Necessary Production Capacity
Work-in-Process Inventory ,[object Object]
Example: Necessary Production Capacity ,[object Object],[object Object],[object Object]
Example: Necessary Production Capacity ,[object Object],[object Object],[object Object],[object Object]
Example: Reduction in WIP ,[object Object],[object Object]
Example: Reduction in WIP ,[object Object],[object Object],[object Object],[object Object]
Successful JIT Applications ,[object Object],[object Object],[object Object]
Changes Required for JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Elements of JIT Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Eliminating Waste in Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Problem Solving and Continuous Improvement ,[object Object],[object Object],[object Object],[object Object],[object Object]
Uncovering Production Problems Water level must be lowered! Quality Problems Material Shortages Machine Breakdowns Workload Imbalances Worker Absenteeism Out-of-Spec Materials Quality Problems In-Process Inventory Production Problems
People Make JIT Work ,[object Object],[object Object],[object Object],[object Object]
TQM and JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Parallel Processing ,[object Object],Op 1 Op 2 Op 3 Op 4 Op 5 Op 6 Op 7 Op 8 ,[object Object],Cycle Time for Each Operation = 1 Hour Total Product Cycle Time = 1 x 5 = 5 Hours ,[object Object],[object Object],Cycle Time for Each Operation = 1 Hour Total Product Cycle Time = 1 x 8 = 8 Hours Op 1 Op 2 Op 3 Op 4 Op 5 Op 6 Op 7 Op 8
JIT: A Pull System ,[object Object],[object Object],[object Object]
Kanban Production Control ,[object Object],[object Object],[object Object]
Kanbans and Other Signals ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Kanban Cards Conveyance Kanban Card Part number to produce: M471-36 Part description: Valve Housing Lot size needed: 40 Container type: RED Crate Card number: 2 of 5 Retrieval storage location: NW53D From work center: 22 To work center: 35
Kanban Cards Production Kanban Card Part number to produce: M471-36 Part description: Valve Housing Lot size needed: 40 Container type: RED crate Card number: 4 of 5 Completed storage location: NW53D From work center: 22 To work center: 35 Materials required: Material no. 744B Storage location: NW48C Part no. B238-5 Storage location: NW47B
How Kanban Operates ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Flow of Kanban Cards and Containers Upstream Work Center #1 Downstream Work Center #2 In-process storage Parts Flow P-Kanban and empty container Full container and P-Kanban C-Kanban and empty container Full container and C-Kanban
Containers in a Kanban System ,[object Object],[object Object],[object Object],[object Object]
Calculating the No of Containers between Work Centers N = Total number of containers between 2 stations U = Usage rate of downstream operation T = Average elapsed time for container to make entire cycle P = Policy variable indicating efficiency... 0 - 1 C = Capacity (number of parts) of standard container
Example: Number of Containers ,[object Object],[object Object],[object Object]
Example:Number of Containers ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Essential Elements of JIT Purchasing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
E-Commerce and JIT Purchasing ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Reducing Inventories through Setup Time Reduction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Setup Time Required for an EOQ
[object Object],[object Object],Setup Time Required for an EOQ
Example: Setup Time Required ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Example: Setup Time Required ,[object Object]
Example: Setup Time Required ,[object Object],[object Object]
Working Toward Repetitive Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object]
Working Toward Repetitive Manufacturing ,[object Object],[object Object],[object Object],[object Object],[object Object]
Benefits of JIT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Wrap-Up ,[object Object],[object Object],[object Object],[object Object],[object Object]

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37020766 jit-and-lean-manufacturing-by-sashi-prabhu

  • 1. Just-In-Time and Lean Manufacturing by Sashi Prabhu
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  • 7. Order-to-Delivery Cycle Distri- bution and Customer Service Custo- mer Places Order Order Entry Engi- neering Design If reqd. Sched- uling Manufacturing Lead Times Purchasing Lead Times Manufacturing Cumulative Lead Time Order-to-Delivery Cycle
  • 8.
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  • 10. Capacity Utilization 10 20 30 40 50 60 70 80 90 100 5 1 3 % Capacity Utilization 11 Production Lead Times (days) 7 9 Traditional Manufacturing JIT Manufacturing
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  • 23. Uncovering Production Problems Water level must be lowered! Quality Problems Material Shortages Machine Breakdowns Workload Imbalances Worker Absenteeism Out-of-Spec Materials Quality Problems In-Process Inventory Production Problems
  • 24.
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  • 30. Kanban Cards Conveyance Kanban Card Part number to produce: M471-36 Part description: Valve Housing Lot size needed: 40 Container type: RED Crate Card number: 2 of 5 Retrieval storage location: NW53D From work center: 22 To work center: 35
  • 31. Kanban Cards Production Kanban Card Part number to produce: M471-36 Part description: Valve Housing Lot size needed: 40 Container type: RED crate Card number: 4 of 5 Completed storage location: NW53D From work center: 22 To work center: 35 Materials required: Material no. 744B Storage location: NW48C Part no. B238-5 Storage location: NW47B
  • 32.
  • 33. Flow of Kanban Cards and Containers Upstream Work Center #1 Downstream Work Center #2 In-process storage Parts Flow P-Kanban and empty container Full container and P-Kanban C-Kanban and empty container Full container and C-Kanban
  • 34.
  • 35. Calculating the No of Containers between Work Centers N = Total number of containers between 2 stations U = Usage rate of downstream operation T = Average elapsed time for container to make entire cycle P = Policy variable indicating efficiency... 0 - 1 C = Capacity (number of parts) of standard container
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