TOYOTA PRODUCTION SYSTEMS

FLOW MANUFACTURING
Kuliah 3
LSiPro FT Untirta
Muhammad Adha Ilhami
Edisi 1 Tahun 2013
Muhammad Adha Ilhami
Prosedur Implementasi JIT
Muhammad Adha Ilhami
Just in Time
Standard
Operation
Leveling/
Heijunka
Flow
Manufacturing
Workplace Improvement / 5S
Awareness
Revolution
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V
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M
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Maintenance
& Safety
Quality
Assurance
Kanban
Jidoka
Change Over
Multiprocess
Handling
Tujuan Pembelajaran
Mampu memahami prinsip Flow Process
Manufacturing
Mampu memahami mengimplementasikan
Flow Process Manufacturing.
Muhammad Adha Ilhami
Flow Process Manufacturing
Definition
Muhammad Adha Ilhami
Flow manufacturing is a pull-driven strategy. At
its core is the principle that demand can be
synchronized with a daily production rate by
properly sequencing items on a flow line that is
replenished frequently by suppliers.
The Reason
Muhammad Adha Ilhami
In this way, inventory is kept to a
minimum, goods are made to
demand, cycle times fall within the
required order-to-deliver response
times and constraints are minimized.
The three critical success factors
Muhammad Adha Ilhami
The three critical success factors for
manufacturers moving into the millennium, as
observed by Industry Directions, are customer
responsiveness, greater efficiencies and retained
profitability.
Responsiveness has moved up in importance as
the competitive playing field has squeezed
companies to out perform their rivals in speed,
flexibility and reliability or lose their standing.
The Principles
Muhammad Adha Ilhami
The principles of flow manufacturing are based
on eliminating waste, streamlining processes,
building to demand and implementing
continuous improvement.
It requires?
Muhammad Adha Ilhami
specific flow training and continually maintained
disciplines
a mechanism for defining and refining optimal line
design
Kanbans and mixed model production sequence
a mathematical model for synchronizing the daily
production rate to actual demand
agreements and signals with suppliers, and the ability to
quickly reflect product engineering changes in the line
design
Kanban calculations, operator instructions and
production reporting
The Challenges
untrained people who resist change
inconsistent discipline
a lack of integrated systems and the
tools needed to support the new
business strategy
Muhammad Adha Ilhami
The Characteristics
Straight and short product flow patterns
Make to order
Single-piece production
Pull System
Short cycle times
Muhammad Adha Ilhami
The Simulation
Muhammad Adha Ilhami
1
st
Simulation
2
nd
Simulation
Think!
What if the product type is more than one? Is
it easy for you to identify?
How about the volume? What problem can
be persisted when it involves a lot number of
products?
Muhammad Adha Ilhami
2
nd

Stat
ion
1
st

Stat
ion
Think!
What if one or more operator can make it to
the plant for many reason?
Can operator from another machine replace
his place?

Respect to People
Muhammad Adha Ilhami
Kanban Assignment
Jelaskan apa itu Kanban?
Bagaimana mekanisme Kanban, aliran Kanban
di lantai produksi, dan apa peranannya?
Beri contoh perhitungan jumlah kartu
kanban, dan jelaskan pula perputaran
sejumlah kartu (yang anda hitung) tersebut di
dalam pabrik?
Muhammad Adha Ilhami
Multi-Process Handling
Assignment
What is the meaning of respect to people
in the japanese point of view?
How can you explain respect to people as
the solution of manpower optimization?
Muhammad Adha Ilhami