Professional Documents
Culture Documents
the
waste of work in progress and finished good inventories)
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Lean Production System
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Toyota/Lean Production System house
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Just-In-Time Systems
What is JIT ?
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Just-In-Time Systems
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What Does Just-in-Time Do?
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What is Waste?
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Sources of Waste
Overproduction
Waiting
Unnecessary transportation
Inventory
Inefficient work methods
Inefficient processing
Unnecessary motions
Product defects
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Waste in Operations (1 of 3)
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Waste in Operations (2 of 3)
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Waste in Operations (3 of 3)
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Just-In-Time
Main Components of JIT
Pull System
Continuous Flow Processing
Takt Time
Flexible Workforce (Shojinka)
3 M’s
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The Pull System
Pull System is a flexible and simple method of controlling/balancing the
flow of resources.
Produce only when your customer demands the product in the required
quantity.
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The Pull & Push System
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Continuous/One-Piece Flow
Producing and moving one item at a time (or a small and consistent batch of
items) through a series of processing steps as continuously as possible, with
each step making just what is requested by the next step.
It is also called the one-piece flow, single-piece flow, and make one & move
one.
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Continuous/One-Piece Flow
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TAKT Time
Takt time is the pace of production required to meet customer demand.
Since takt time is defined by the customer, it becomes a very important number
in a lean environment.
How:
Only 2 variables are used to calculate Takt time: Available Time &
Customer Demand (schedule):
Available time is total shift time minus meal and scheduled break times
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TAKT Time
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Flexible Workforce (Shojinka)
Flexible Workforce (Shojinka):
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Flexible Workforce (Shojinka)
Multi-machine Handling
Type of Part
A
B Unfinished Parts
D
Machine 1
Finished Products
Machine 2 person handles one process, one machine
One
Machine 3 23
Flexible Workforce (Shojinka)
Multi-process Handling
Type of Part
A B C D
Machine 1
Machine 2
Machine 3
Machine 4
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3 M’s
3 M’s
MUDA = Non-Value Added
MURA =Overburden
MURI = Unevenness
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Muda . Mura . Muri
12 TONS
1 TON
4 ton
Capacity : 4 tons
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Muda . Mura . Muri
X 2 = MURI (OVERBURDEN)
= MURA (UNEVENNESS)
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Muda . Mura . Muri
The most efficient way to deliver 12 tons of good to the destination is:
NO MURI
(OVERBURDEN) X 3 = NO MUDA
(NO WASTAGE)
NO MURA
(NO UNEVENNESS)
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Kanban
What is
Kanban?
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Kanban
Kanban is one of the Lean tools designed to reduce the idle time in a production
process. The main idea behind the Kanban system is to deliver what the process
needs exactly when it needs it.
In Japanese, the word “Kan” means “card" and "ban" means “signal," so Kanban
refers to signal cards. Lean uses visual cards as a signaling system that triggers an
action to supply the process with its needs either from an external supplier or from
a warehouse.
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Kanban
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Benefits of JIT
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Jidoka - Automation
What is Jidoka/Automation?
Providing machines and operators the ability to detect when an abnormal
condition has occurred and immediately stop work. This enables operations
to build in quality at each process and to separate men and machines for
more efficient work.
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Jidoka - Automation
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Jidoka - Automation
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Jidoka - Automation
Jidoka Steps
Why Jidoka?
• Increase quality
• Lower costs
• Improve customer service
• Reduce lead time
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Prevention Techniques
• Poka Yoke - Mistake-Proofing
– Visual control of quality
– Prevents defects from happening
• Andons
– Commonly lights to signal production line status
• Red: line stopped
• Yellow: call for help
• Green: all normal
– Andon signals require immediate attention
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Poka Yoke – Mistake Proofing
What is it for?
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Poka Yoke - Examples
Spellcheck:
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Andon
Andon is an information tool which provides instant, visible and audible
warning to the Operations team that there is a abnormality within that
area.
When the equipment shuts down because of a quality problem, flags or
light, usually with accompanying music, signal that help is needed to solve
the problem.
This signaling system is called the andon system.
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Visual Management Andon Lamp
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Benefits of Lean Production
Lean will improve:
Quality performance, fewer defects and rework.
Fewer Machine and Process Breakdowns.
Lower levels of Inventory.
Greater levels of Stock Turnover.
Less Space Required.
Higher efficiencies, more output per man hour.
Improved delivery performance.
Faster Development.
Greater Customer Satisfaction.
HIGHER PROFITS!
INCREASED BUSINESS!
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