LEAN MANUFACTURING JIT KANBAN

GROUP NO : 06
Mayur Avhad - 22 Navketan Gaikwad 24 Pratik Gole 31 Rajesh Sharma 35 Sushil Pawar 60 Amit Prasad -

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WHAT IS LEAN MANUFACTURING

Lean Production (also known as the Toyota Production System) is, in its most basic form, the systematic elimination of waste, remove variability and improve throughput. Lean Production concentrates on producing more value for a customer while reducing expenditure of resources. It includes;

Space
Labor Inventory

Money Time

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1. ELIMINATE WASTE
Waste is anything that does not add value from the customer point of view

Storage, inspection, delay, waiting in queues, and defective products do not add value and are 100% waste
Other resources such as energy, water, and air are often wasted Efficient, sustainable production minimizes inputs, reduces waste

Traditional housekeeping has been expanded to the 5 Ss

Sort/segregate when in doubt, throw it out Simplify/straighten methods analysis tools Shine/sweep clean daily Standardize remove variations from processes Sustain/self-discipline review work and recognize progress Two additional Ss Safety build in good practices Support/maintenance reduce variability and unplanned downtime
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SEVEN WASTES OF PRODUCTION

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2. REMOVE VARIABILITY

JIT systems require managers to reduce variability caused by both internal and external factors
Variability is any deviation from the optimum process Inventory hides variability Less variability results in less waste

Sources of Variability
1. 2. 3. Incomplete or inaccurate drawings or specifications Poor production processes resulting in incorrect quantities, late, or nonconforming units Unknown customer demands

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3. IMPROVE THROUGHPUT
The time it takes to move an order from receipt to delivery The time between the arrival of raw materials and the shipping of the finished order is called manufacturing cycle time A pull system increases throughput By pulling material in small lots, inventory cushions are removed, exposing problems and emphasizing continual improvement Manufacturing cycle time is reduced Push systems dump orders on the downstream stations regardless of the need

2011 Pearson Education, Inc. publishing as Prentice Hall

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JUST-IN-TIME (JIT)
Powerful strategy for improving operations Materials arrive where they are needed when they are needed

Identifying problems and driving out waste reduces costs and variability and improves throughput
Requires a meaningful buyer-supplier relationship
Big lot sizes Lots of inventory PUSH material to next stage

Pre-JIT: Traditional Mass Production

Big purchase shipments

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Lower per unit cost Big pushes of finished goods to warehouses or customers

Post-JIT: Lean Production

Smaller shipments Smaller lots Faster setups Less inventory, storage space PULL material to next stage

Minimal or no inventory holding cost

Goods are pulled out of plant by customer demand

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THREE ELEMENTS OF JIT

2011 Pearson Education, Inc. publishing as Prentice Hall

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ELEMENTS OF JIT
JIT manufacturing focuses on production system to achieve value-added manufacturing

TQM is an integrated effort designed to improve quality performance at every level

Respect for people rests on the philosophy that human resources are an essential part of JIT philosophy JIT Manufacturing is a philosophy of value-added manufacturing Achieved by focusing on these elements: Inventory reduction - exposes problems Kanbans & pull production systems Small lots & quick setups Uniform plant loading

Flexible resources
Efficient facility layouts

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ROLE OF INVENTORY REDUCTION

Inventory = Lead Time (less is better) Inventory hides problems

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KANBAN
Kanban is the Japanese word for card The card is an authorization for the next container of material to be produced A sequence of kanbans pulls material through the process Many different sorts of signals are used, but the system is still called a kanban

Material/Parts Supplier Work cell

Final assembly

Finished goods

Customer order

Kanban Kanban Kanban

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JIT MANUFACTURING: THE PULL SYSTEM (KANBAN)

Uses simple visual signals to control production
Workcenter A Workcenter B

Workcenter B uses parts produced by Workcenter A

How can we control the flow of materials so that B always has parts and A doesnt overproduce?

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KANBAN CARD
Signal to Produce
Workcenter A Workcenter B

Signal to Pull
Workcenter A Workcenter B

Kanban Card

When a container is opened by Workcenter B, its kanban card is removed and sent back to Workcenter A. This is a signal to Workcenter A to produce another box of parts.

Empty box sent back. Signal to pull another full box into Workcenter B. Question: How many kanban cards here? Why?

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HOW MANY KANBAN CARD?

DT(1 x) y C
y = number of kanban cards D = demand per unit of time T = lead time C = container capacity X = fudge factor

Example : Hourly demand = 300 units Lead time = 3 hours Each container holds 300 units Assuming no variation in lead-time or demand (x = 0): y = (300 3) / 300 = 3 kanban cards

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SMALL LOT SIZES & QUICK SETUPS

Example : Small lots mean less average inventory and shorten manufacturing lead time Small lots with shorter setup times increase flexibility to respond to demand changes

Ultimate goal is single unit lot sizes

Strive for single digit setups- < 10 minutes Setup reduction process is well-documented External tasks- do as much preparation while present job is still running Internal tasks- simplify, eliminate, shorten steps involved with location, clamping, & adjustments

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UNIFORM PLANT LOADING

A level schedule is developed so that the same mix of products is made every day in small quantities Leveling the schedule can have big impact along whole supply chain

Weekly Production Required A B C D E Traditional Production Plan Monday Tuesday AAAAA BBBBB AAAAA BBBBB JIT Plan with Level Scheduling Monday Tuesday AABBBB AABBBB CDEE CDEE

10 units 20 units 5 units 5 units 10 units Wednesday BBBBB BBBBB Wednesday AABBBB CDEE Thursday DDDDD CCCCC Thursday AABBBB CDEE Friday EEEEE EEEEE Friday AABBBB CDEE
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FLEXIBLE RESOURCES
Moveable, general purpose equipment: Portable equipment with plug in power/air Drills, lathes, printer-fax-copiers, etc. Capable of being setup to do many different things with minimal setup time

Multifunctional workers: Workers assume considerable responsibility

Cross-trained to perform several different duties

Trained to also be problem solvers

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EFFECTIVE FACILITY LAYOUTS

Workstations in close physical proximity to reduce transport & movement Streamlined flow of material Often use: Cellular Manufacturing (instead of process focus)

U-shaped lines: (allows material handler to quickly drop off materials & pick up finished work)

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BENEFITS OF JIT
Reduction in inventories Improved quality Reduced space requirements Shorter lead times Lower production costs Increased productivity Increased machine utilization Greater flexibility

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JIT and Competitive Advantage

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THANK YOU!!!

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