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PURPOSES OF JIT
Primary Purpose: Profit through cost reduction (or improvement of Productivity) This is attained through WASTE elimination. Other important purposes: Quantity control: JIT, Kanban & Autonomation (visual control system) Quality control: Autonomation, improvement by small groups, functional management Respect for humanity : Flexible work force (adapt to demand changes), capitalize workers ideas.
TYPES OF WASTE
Excessive production resources (primary waste): excessive workforce excessive facilities excessive inventories unnecessary capital investment Overproduction (secondary waste - the WORST waste): leads to Excessive inventories (tertiary waste): extra jobs make overproduction invisible. adds losses in opportunity cost lead to Unnecessary capital investment (fourth waste): adds facility depreciations and overhead cost
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Over-production Waste
Definition Producing more than needed Producing faster than needed
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Over-production Waste
Characteristics:
Inventory Stockpiles Extra equipment/oversized equipment Unbalanced Material Flow Extra Part Storage racks Extra Manpower Batch Processing Complex Inventory Management Excessive Capacity/Investment Additional Floor Space/Outside Storage Hidden Problems Excessive Obsolescence Large Lot Sizes Building Ahead
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Over-production Waste
Causes: Incapable Processes Just in Case Reward System Lack of Communication Local Optimization Automation in the Wrong Places Cost Accounting Practices Low Uptimes Lack of Stable/Consitent Schedules
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Transportation Waste
Definition Any Material Movement That Does Not Directly Support a Lean Manufacturing System
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Transportation Waste
Characteristics: Extra carts, fork lifts, dollies Multiple Storage Locations Extra Material Racks Complex Inventory Management Extra Facility Space Incorrect Inventory Counts Damaged Material
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Transportation Waste
Causes: Large Lot Processing Unleveled Schedules Lack of 5 Ss Lack of Visual Controls Improper Facility Layout Large Buffers and In Process Kanbans
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Processing Waste
Definition Effort Which Adds No Value To a Product or Service. Enhancements which are Transparent to The Customers or Work Which Could Be Combined with Another Process.
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Processing Waste
Characteristics: Process Bottlenecks Lack of Clear Customer Specifications Endless Refinement Redundant Approvals Extra Copies/Excessive Information
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Processing Waste
Causes: Engineering Changes Without Processing Changes Decision Making at Inappropriate Levels Inefficient Policies and Procedures Lack of Customer Input Concerning Requirements
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Inventory Waste
Definition Any Supply in Excess of Process Requirements Necessary to Produce Goods or Services Just in Time.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Inventory Waste
Characteristics: Extra Space on Receiving Docks Material Between Processes Stagnated Material Flow LIFO instead of FIFO Extensive Rework When Problems Surface Long Lead Time for Engineering Changes Additional Material Handling Resources (Men, Equipment, Racks, Storage Space)
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Inventory Waste
Causes: Incapable Processes Uncontrolled Bottleneck Processes Incapable Suppliers Long Change Over Times Management Decisions Local Optimization Inaccurate Forcasting Systems
Over Production Wait Time Process Defects
Inventory Level
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Motion Waste
Definition Any Movement of People Which Does Not Contribute Added Value To The Product or Service
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Motion Waste
Characteristics: Looking for Tools Excessive Reaching or Bending Material Too Far Apart (Walk Time) Equipment for Moving Parts Extra Busy Movements While Waiting
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
Motion Waste
Causes: Equipment, Office & Plant Layout Lack of 5 Ss Lack of Visual Controls Inconsistent Work Methods (Standardized Work) Large Batch Sizes
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
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7 7 Wastes, Wastes, Applied Applied Materials, Materials, Lean Lean Manufcaturing, Manufcaturing, Supplier Supplier Copy, Copy, 1999. 1999.
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