生产计划chap6.ppt
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生产计划chap6.ppt
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Just-in-timeProf.JiangZhibinDept.ofIE,SJTUToolsofLeanManufacturingPullSystems/KanbanAToolforImplementingPullSystemsLeanProductionThroughWasteEliminationOperationalStabilityJITQualityattheSourcePeopleJITGoalsnZerodefectsnZeroexcesslotsizeorlotsizeofonenZerosetupsnZerobreakdownsnZerohandlingnZeroleadtimenZeroSurgingnLevelproductionplananduniformproductmixNEEDTOREDUCECOSTTraditionalMethod(Push)SellerDrivenModernMethod(Pull)CustomerDrivenSellingSellingPricePriceProfit=Profit=CostCost+(SELLER)SellingSellingPricePrice-CostCost=PROFITPROFIT(MARKET)JustinTimenHistory-Japann1980sconclusionnJapaneseindustryworked“smart”-JITnThinkofJITasminimumstockproductionnTypeofrelationship:
close&intimate?
JITninternalJIT-inclient-serverstreamnexternalJITJapaneseexperienceWasteinoperationsfromnoverproductionnwaitingtimentransportationninventorywastenprocessingnmotion/movementnproductdefectsconcentrateeffortonshopfloorCQIfocusstaffownershipofproblemsMinimizingWaste:
InventoryHidesProblemsWorkinprocessqueues(banks)ChangeordersEngineeringdesignredundanciesVendordelinquenciesScrapDesignbacklogsMachinedowntimeDecisionbacklogsInspectionbacklogsPaperworkbacklogidentifydefectsfromasupplierearlyintheprocesssavesthedownstreamworkidentifydefectiveworkfromupstreamstations,savesthedownstreamworkForecastrandomordersMasterproductionschedule(MPS)MRP1DesignchangesBillofmaterialStockmovementsInventoryrecordReports8AggregatePlan(productgroups)FirmordersFromAggregatetoMPStoMRP1Time-phasedplanhowmany+whenwewillbuildeachenditem.MRP2JITJust-In-Time(JIT)nasystemforhigh-volumeproductionwithminimalinventory(rawmaterials,WIP,finishedgoods).ninvolvesntimedarrivalsworkstationJITnreducedbufferstocksnnowasteinproductionsystemna“Pull”systemthrutheplantnamanagementphilosophynexposeproblems&bottlenecksnTakeawaysecurityblanket”nstreamlinedproductionnfactory&warehousenetworksparticipationindustrialengineering/basicscontinuingimprovementTQMreducingsetuptimessmallerlot/ordersizessizesstableenvironmentsupplypartnershipRequiresJITRequirements1KanbanPullnDemandpullnBackflushnReducebatch/lotsizesWorkwithsuppliersReduceleadtimesFrequentdeliveriesProjectusagerequirementsQualityexpectationsReduceinventoryinStoresTransitConveyorscalculationfromMRP&EOQsJITRequirements2QualityWorkerresponsibilitySQCEnforcecomplianceErrorproffingAutomaticinspectionStabiliseScheduleLevelscheduleUnderutilizecapacityOperationsDesignLinkoperationsBalanceworkstationcapacitiesReviewlayoutforflowStresspreventivemaintenanceReducelotsizesReducesetup/changeovertimePeopleFocusnpayharmonisationnsupportiveunionsnsubcontractornetworksnhands-onmanagerstylenqualitycommitment&groupinvolvementJITRequirements3ProductDesignImprovementnDFM&processdesignnModules&fewerpartsnQualitystandardsnupgradehousekeepingnclarifyprocessflowsnreviseequipment&processtechnologiesProblem-solvingRootproblemLong-termsolutionTeamcontributionLine-specialistcooperationLearningMeasureperformanceCQIMonitor&reportJITandDemand-PullCustomerSupplierSupplierSupplierSupplierFinalAssemblyFabricFabricFabricFabricSubassSubassCall(Kanban)&PullCall(Kanban)&PullCall(Kanban)&PullClientServerStreamingAvoidtoomuchmaterialstocks&WIPIncreasematerialscoordination&movementBinSawSupplierslocalwarehouseFinishedGoodsWarehouseGrinderLatheBinCallformoreMaterialswarehouseBinBinBinBinCustomerJITdeliveriesCallformoreWhatiskanban?
ndevelopedatToyota1950stomanagelinematerialflows.nKanban(Kan=card,Ban=signal)nsimplemovementsystemn“cards”tosignal&communicatereorderinformationnboxes/containerstotake“lots”ofpartsfromoneworkstationtoanother(client-server).nServeronlydeliverscomponentstoclientworkstationas&whenneeded(called/pulled).nminimisestorageintheproductionarea.nWorkstationsonlyproduce/delivercomponentswhencalled(theyreceivecard+emptycontainer).nThework-stationproducesenoughtofillthecontainernKanban=anauthorizationtoproducemoreinventorynWethuslimittheamountofinventoryinprocess.BENEFITSOFKANBANnAninformationnetworkusedtocontrolproductionquantitiesnAcommunicationprocessthatcontrolsthemovementofmaterialnAcostreduction(wasteelimination)toolthatpreventsoverproductionnAqualitycontrolenforcerbecauseitlimitslotquantitiestosmallamounts,therebyallowingdefectstobeidentifiedearlyinthemanufacturingprocessBENEFITSOFKANBAN(cont.)nManagesjust-in-timeproductionnGivesspecificpartnumber,quantity,location,andtimedemandstolowerworkcentersnIdentifyexcessinplantinventorylevelsnIdentifypotentialinventoryshortages(lowstockindicators)nLimitsqualityrejectsbyreducinglotsizeproducedKANBANPRE-CONDITIONSTherearefourpre-conditionsforthesuccessfulimplementationofKanbanPointofusePoint
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