Professional Documents
Culture Documents
JIT and Lean
JIT and Lean
JIT (Just-in-time)
Just-In-Time
and
Lean Systems
By Prof. Jerome Alvarez
JIT (Just-in-time)
Just-In-Time Techniques
Company wide
Commitment to
education
Eliminate redundancy
Reduce all Inventory
Establish Continuous
Improvement Goals
Have a Defect
Prevention Program
Reduce Setup Times
Build Products to
Specification
10/3/2015
Managing Relationships
-
Keiretsu:
Suppliers become part of a company coalition.
Combination of few suppliers and vertical integration
o
Lean Manufacturing or
Lean Production
The
7 Deadly
Wastes (Mudas)
By: Prof. Jerome Alvarez
10/3/2015
7 Waste of Lean
Manufacturing
1.
2.
3.
4.
5.
6.
7.
Transport
Inventory
Motion
Waiting
Over-Processing
Overproduction
Defects
7 Waste of Lean
Manufacturing
1.
2.
3.
4.
5.
6.
7.
Waiting
Over Production
Rejects
Motion
Processing
Inventory
Transport
8 Waste
Defective Production
Overproduction
Waiting
Non-used Employee Talent (the 8th form)
Transportation
Inventory
Motion
Excessive (Over) Processing
Transportation Waste
unnecessary material movement
unnecessary tools or equipment movement
Causes
poor route planning
distant suppliers
complex material flows
poor layout
disorganized workplace
line imbalance
10/3/2015
Inventory Waste
excessive process (WIP) inventories
excessive raw material inventories and supplies
Causes
over-production
imbalanced line
big batch sizes
long lead times
local optimization (turf mentality)
large minimum order quantities
high rework rate
JIT-incapable suppliers
lack of material requisition and issuance standards
Motion
Unnecessary motions are
those movements of man or
machine which are not as
small or as easy to achieve
as possible.
Examples:
Bending down to retrieve
heavy objects at floor
level when they could be
fed at waist level to
reduce stress and time to
retrieve.
Excessive travel between
work stations
Excessive machine
movements from start
point to work start point
are all examples of the
waste of Motion.
Motion Waste
unnecessary movement and motions of
worker Causes
poor lay-out and housekeeping
disorganized work place and storage
locations
unclear, non-standardized work
instructions
unclear process and materials flow
10/3/2015
Processing Waste
non-value added man processing
non-value added machine processing
Causes
unclear customer specifications
frequent engineering changes
excessive quality (refinements)
inadequate value analysis/value engineering
unclear work instructions
Overproduction Waste
producing more than what is needed
producing faster than what is needed
Causes
volume incentives (sales, pay, purchasing)
high capacity equipment
line imbalance; poor scheduling/shifting
poor production planning
cost accounting practices that encourage
build up of inventory
Defects Waste
processing due to the production of defects
processing due to rework or repair of defects
materials used due to defect and rework
Causes
unclear customer specifications
incapable processes
lack of process control
unskilled personnel
departmental rather than total quality
incapable suppliers
10/3/2015
Additional Wastes:
Waste
Waste
Waste
Waste
Waste
of Talent
of Skills
of Resources
of Supplies
of Space
Source:
http://leanmanufacturingtools.org/77/the
-seven-wastes-7-mudas/
http://mubashirghori.blogspot.com/2015/
02/7-waste-in-lean-manufacturing-sixsigma.html
https://en.wikipedia.org/wiki/Lean_manuf
acturing