JITP

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KAIZEN in Just-In-Time Production System

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Hasan Haider, NPO Pakistan
The challenges for our Industry
Production Costs
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Customer Price Net Margin
Cheaper
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Reduce Cost
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We need to be able to do three things well, all at the same time! We need to be able to do three things well, all at the same time!
Reduce Lead Time
Improve Quality
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Faster
Better
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Jay-eye-tea
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KAIZEN in Just-In-Time Production System
Toyota Production System

Hasan Haider, NPO Pakistan 3
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JIT
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Reduction of Production Lead Time
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What issue/concept will be most important to you in the 1990s ?
Source: Sanno College Seisan-shi Textbook
Meeting the Challenge

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Requires a new way of thinking. Training in new methods. Leadership and commitment at all levels. Implementation - do it.
Need to do more than talk. We learn by doing. Improvements dont have to be expensive.
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JIT - A set of tools that fit together

er ustom r C lie Supp ships ion Relat
Ta k t Time
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Work Cells
MultiProcess
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Ma int en an ce
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tion onoma Aut
Lev el Dem and
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On Pie e c Flo e w
y Qualit n ce ssura A
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Sa fe ty
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Visual
Controls
mall S Lot Size m ste y ll S Pu
Spiri t
up S et n ctio u Red
Sta nda rd Wo rk
e tak Mis g ofin Pro

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Ba Lin la e n g ci n
Attack On Waste
JIT - A Strategy Based on Lead Time
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Opportunity
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Lead Time
Adding Value
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A strategic focus to economically make drastic reductions in lead times to better serve the customer.
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JIT - A Toolset For Eliminating Waste

JIT Tools used to identify and eliminate waste from the process.
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$ $ $
$ $
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Result: Shorter lead times, reduced costs.
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Same Value-Add Reduced lead time Reduced costs

The Spirit of Improvement

Improvement is everyone's job. Think of ways to make ideas work. Dont say cant. 50% improvement is OK. Dont substitute money for brains. Ask Why?, five times. Improvement is not made from a conference room. More ideas are better, especially from people close to the problem. Follow up to make sure the idea is working. Improvement is endless.
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Purpose of a Kanban System

1) Control of inventory movement. 2) Authorize production. 3) Regulate amount of inventory in the system. 4) Provide a visual control that makes overproduction obvious. 5) A tool for driving continuous improvement.
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Rules for Kanban Systems

1) Pull from the downstream process (or customer) drives the system. 2) All product or inventory is under kanban control. 3) Only an empty kanban authorizes production. 4) Never pass a known defect downstream. 5) Use gradual kanban reductions to drive improvement.
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Kanban
Is a signal that:
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The signal can be a:

Card Square Box Pigeon hole Light Etc.
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Authorizes production Authorizes movement Limits inventory
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How Many Kanbans?

(True Lead Time + Safety Time) = Total Time
Total Time x Production Requirement = Units in Pipeline
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Units in Pipeline
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= Number of Kanbans
Units per Kanban
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Pull Production System

Definition A customer driven system that produces and moves a product/service only when the customer needs it
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Kanban 1 Work Center A
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Kanban 2
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Work Center B
Kanban 3
Work Flow
Push System
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Pull System
Push and Pull System
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KANBAN
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Supermarket Concept & KANBAN System
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Just-In-Time (JIT) system

The concept of producing or conveying only those units needed, just when they are needed, in just the amount needed, at all stages of production.
By Toyota Motor Company
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Mistake Proofing Overview Poka-Yoke
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Mistake-proof (Poka-yoke)
Note: Poka ----- Carelessness; Absent-mind Yoke----- Elimination
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This refers to the thoughtful use of devices which eliminates operators careless mistakes.
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Mistake-Proofing
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Purpose The mistake-proofing process prevents mistakes before they create defects.
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What is Poka-Yoke Mistake-Proofing ?
An Organized Approach to a Common Sense
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Recognizes People Forget and Make Errors Uses Common Sense (Mistake Proofing) Ideas and Methods in Product and Process Design to Eliminate Human and Mechanical Errors
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Mistake Proofing Is a Philosophy That:
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Way of Eliminating Defects
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Mistake-Proofing
Why do mistake-proofing?

Improve quality Eliminate rework Reduce cost Improve schedule performance (especially in relation to the predictability of cycle times Zero Quality Control (Zero Defects) Total Customer Satisfaction
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Quality, Cost, Delivery, Safety, Morale

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Benefits and Results

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Benefits
Results

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Makes it easy to do the right things in the right order in the right way. Prevents accidentally doing the wrong things in the wrong order in the wrong way
Improves quality Reduces costs Improves on-time delivery Reduces or eliminates accidents Improves morale
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Mistake-Proofing in Everyday Life

Car safety belt warning light or buzzer. Clothes iron that shuts itself off if left on inadvertently. A car that cannot be started in gear.
Beeper to Indicate the Lights Are Left on When the Keys Are Removed From the Ignition Switch Cruise Control Which Shuts off When the Brakes Are Applied Turn Signal Warning Beep When Left on
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Microwave ovens that will not start with the door open
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Garage door opener with safety reversing switch.
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Examples of Common Devices
Safety Features in the Products Carrier Produces:
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Thermostat Which Prevents Heat and Cool From Being Turned on at the Same Time
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Panels Are Removed
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That Shuts Down the Furnace When
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Gas Furnace With an Interlock Switch
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Examples of Common Devices
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Fire Drills, Safe Exit Plans Pressure Switches, Monitors Panic Door Hardware on All Exterior Doors Fixtures Which Prevent Parts From Being Incorrectly Positioned Tools Which Reach a Specified Torque then Shut off
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Palm Buttons Light Curtains Brake Monitors
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In Manufacturing: Safety Devices on Presses
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Why Do Mistake Proofing ?

Customers Demand 100% Defect Free Products

Scrap
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Missed Schedules Lean Manufacturing Will Not Tolerate Mistakes
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Rework
One Piece Flow Demands Good Quality Parts All the Time Batch Processing Can Hide Mistakes With Excess Inventory Hasan Haider, NPO Pakistan
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Cost Pressures Dont Allow for Continued Mistakes
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100% Inspection Wont Provide 100% Defect Free Products
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100% Inspection Exercise
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Please Find and Count All the Fs in This Letter

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John Foster
Quality Engineer
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3-21-92
Date
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Finished Files Are The Result Of Years Of Scientific Study Combined With The Experience Of Years
7 Fs Total - How Many Did You Each Find ?

Please Find and Count All the Fs in This Letter
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John Foster
Quality Engineer
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3-21-92
Date
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Finished Files Are The Result Of Years Of Scientific Study Combined With The Experience Of Years
Is 99.9% Quality Good Enough for You ?

If It Is, Then You Wont Mind 0.1% Defectives:
Ill do better next time!
Post Offices in New York State Lose 61,626 Pieces of Mail Per Day Chicago OHare International Airport Has 1,264 Unsafe Arrivals / Departures Per Year
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288 Babies Per Year
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Doctors in New York State Hospitals Drop
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Examples of Errors Vs. Defects

Leave the Iron on Then Leave for Work
Error - (Cause)
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Defect - (Effect)
Pump Diesel Fuel Into Your Gas Tank
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Run a Red Light
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Not Setting the Timer Properly on Your Toaster
Placing the Original in Your Copier Face up. Running Out of Ink on Your Date Coder
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7 Step Mistake Proofing Process 1. Describe the Defect in Detail. 2. Identify Process or Operation Where Defect Can First Be Discovered - Where Defect has Actually Been Created. 3. Map the Sequence of Tasks by Reviewing Current Method or Procedures (the Way It Is Supposed to Be Done). 4. Observe the Process (the Way It Is Actually Being Done). 5. Identify Errors - Gaps Between #3 and #4 - the Differences Between How We Should Do It and How We Actually Do It (Theory Vs. Actual). 6. Identify Mistake Proof Device(s) Required to Prevent or Detect Error Conditions. 7. Trial and Error Perfection of Original Mistake-proof Device Until Solution Eliminates Defect.
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Types of Mistake-Proof Devices
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1. Guide / Reference / Interference Other Prevention Techniques: Rod or Pin 2. 3. 4. 5. 6. 7. 8. 9. Template Limit Switch / Microswitch Counter Odd-part-out Method
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A list of Mistake-proof devices, certainly not all inclusive, that can be used to respond to Red Flags and prevent errors and/or defects:
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1. Eliminate the Condition
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2. Redesign for Symmetry 3. Redesign for Asymmetry Mistake-proof Your Mistakeproof
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Sequence Restriction Standardize and Solve Critical Condition Indicator Detect Delivery Chute
10. Stopper / Gate 11. Sensor

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Detecting and Avoiding Defects

What are the Five Best Mistake-Proof Devices? Human errors are usually inadvertent. Mistake-proof devices help us avoid defects, even when inadvertent errors are made. Mistake-proofing helps build quality into processes. Here are five examples of mistake-proofing for detecting or avoiding defects caused by human errors.
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UPPER DIE
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GUIDE PINS LOWER DIE
Guide Pins of Different Sizes
Error Detection and Alarms
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Detecting and Avoiding Defects - cont...
Limit Switches
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PRESS LIMIT SWITCH DETECTS CORRECT PLACEMENT
PRODUCT
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TO OPERATING CIRCUIT
CLEAR BUTTON DIGITAL COUNTER
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Counters
Checklists
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Mistake Proofing Example

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Before Mistake-Proofing After Mistake-Proofing
Locating Angles Locating Angles
Correct
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Locating Angles
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Guide Pin
Incorrect
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Omitted Washer
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Before Mistake-Proofing
After Mistake-Proofing
Container
During assembly, lockwashers are frequently omitted. Without the lockwashers, the bolts can loosen.
The correct number of each part required for the operation is precounted and provided in a container.
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Correct
Fire Extinguisher Reservoir Bottles
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Hose to Area B Hose to Area A
Hose to Area A
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Incorrect
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Hose to Area B
Fire Extinguisher Reservoir Bottles
Fire Extinguisher Reservoir Hose to Area B Bottles
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Female Different size connectors
Male
Hose to Area A
Hose connections can be reversed. If a fire occurred in Area A, Area B would be doused.
By redesigning the connectors to two different sizes and types (female and male), it is no longer possible to mix up hose connections.
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Manual measuring and layout of trim periphery
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Locating Holes
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Panel Trim Lines
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Trim Template Locating Holes Panel Trim Lines
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Results in inaccurate location of trim lines, creating a defective part when the part is trimmed.
Use of template allows accurate layout of trim lines.


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Before Mistake-Proofing After Mistake-Proofing
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Covers were frequently scratched when the screwdrivers slipped out of the screw slot and slid against the plastic covers.
The cause of the trouble was scrutinized and a change was made in the shape of the screw slot to prevent the screwdriver from slipping. Scratches caused by the screwdriver slipping have been completely eliminated.
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Poka-yoke Example 1
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Screw driver slips and scratches the Source: Poka-yoke Daizukan Nikkan-kogyo product.
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Poka-yoke Example 2
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Non-defective Defective Fool-proof device
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Source: Poka-yoke Daizukan Nikkan-kogyo

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Analysis of Carelessness
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Kanebo Chemical, 1989
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Wrong operations
23%
Negligence (Forgetfulness)
48%
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Source: Poka-yoke activities Kanebo Chem.,1991
Auto-nomation (Jidoka)
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Jidoka refers to the ability of production equipment, including a single machine, to sense a malfunction of the machine.
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Autonomation (Jidoka): Automation

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with a human touch

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Stop!
I dont know. Simple automation
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Jidoka
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The
goal of single minute set-up movement is to reduce the setup time to less than 10 minutes.
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Single minute exchange of die (SMED)
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Stamping Machine
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The Trick of the Magic

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Advanced Preparation
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Masking tape
Paint an arrow
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Trash can
Spreadsheet
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Example (1)
Source: The Japan HR Association
U-shaped washer Nut and bolt

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Source: H. Hirano Me de mite wakaru JIT Seisan Hoshiki Nikkan-kogyo Shinbun, Hasan Haider, NPO Pakistan
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Pear-shaped holes
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Example (2)
Seven Wastes
1. 2. 3. 4. 5. 6. 7. Waste from over-production Waste of waiting time Transportation waste Processing waste Inventory waste Waste of motion Waste from product defectives
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pd fM

KAIZEN in Just-In-Time Production System

Hasan Haider, NPO Pakistan

The challenges for our Industry

Customer Price Net Margin

Reduce Lead Time

Hasan Haider, NPO Pakistan

KAIZEN in Just-In-Time Production System

Toyota Production System

Reduction of Production Lead Time

What issue/concept will be most important to you in the 1990s ?

Source: Sanno College Seisan-shi Textbook

Meeting the Challenge

Hasan Haider, NPO Pakistan

JIT - A set of tools that fit together

tion onoma Aut

Lev el Dem and

mall S Lot Size m ste y ll S Pu

e tak Mis g ofin Pro

Hasan Haider, NPO Pakistan

JIT - A Strategy Based on Lead Time

JIT - A Toolset For Eliminating Waste

Result: Shorter lead times, reduced costs.

Same Value-Add Reduced lead time Reduced costs

The Spirit of Improvement

Hasan Haider, NPO Pakistan

Purpose of a Kanban System

Hasan Haider, NPO Pakistan

Rules for Kanban Systems

Hasan Haider, NPO Pakistan

The signal can be a:

Authorizes production Authorizes movement Limits inventory

Hasan Haider, NPO Pakistan

How Many Kanbans?

Units per Kanban

Hasan Haider, NPO Pakistan

Pull Production System

Supermarket Concept & KANBAN System

Just-In-Time (JIT) system

Mistake Proofing Overview Poka-Yoke

Hasan Haider, NPO Pakistan

What is Poka-Yoke Mistake-Proofing ?

An Organized Approach to a Common Sense

Mistake Proofing Is a Philosophy That:

Way of Eliminating Defects

Hasan Haider, NPO Pakistan

Quality, Cost, Delivery, Safety, Morale

Benefits and Results

Hasan Haider, NPO Pakistan

Mistake-Proofing in Everyday Life

Garage door opener with safety reversing switch.

Hasan Haider, NPO Pakistan

Examples of Common Devices

Safety Features in the Products Carrier Produces:

Panels Are Removed

That Shuts Down the Furnace When

Gas Furnace With an Interlock Switch

Hasan Haider, NPO Pakistan

Examples of Common Devices

Palm Buttons Light Curtains Brake Monitors

In Manufacturing: Safety Devices on Presses

Why Do Mistake Proofing ?

Missed Schedules Lean Manufacturing Will Not Tolerate Mistakes