Professional Documents
Culture Documents
Raw
Material
Supplier
Final
Assembly
Customer
FGI
PUSH
Raw
Material
Supplier
Final
Assembly
Customer
FGI
PULL
Information Flow
Material Flow
Push System
Every worker maximizes own output, making as many
products as possible
Pros and cons:
Focuses on keeping individual operators and workstations
busy rather than efficient use of materials
Volumes of defective work may be produced
Throughput time will increase as work-in-process increases
(Littles Law)
Line bottlenecks and inventories of unfinished products will
occur
Hard to respond to special orders and order changes due to
long throughput time
Pull System
Production line is controlled by the last operation,
Kanban cards control WIP
Pros and cons
Controls maximum WIP and eliminates WIP
accumulating at bottlenecks
Keeps materials busy, not operators. Operators work
only when there is a signal to produce.
If a problem arises, there is no slack in the system
Throughput time and WIP are decreased, faster
reaction to defects and less opportunity to create
defects
WHAT IT DOES
Attacks waste
Management philosophy
Pull system though the plant
WHAT IT ASSUMES
WHAT IT REQUIRES
Employee participation
Stable environment
Industrial engineering/basics
Continuing improvement
Total quality control
Small lot sizes
Kaizen
5
A Little History!
Ford: Design for manufacturing
Start with an article that suits and then study to find
some way of eliminating the entirely useless parts.
This applies to everything a shoe, a dress, a
house, a piece of machinery, a railroad, a
steamship, an airplane. As we cut out useless parts
and simplify necessary ones, we also cut down the
cost of making. ...But also it is to be remembered
that all the parts are designed so that they can be
most easily made."
A Little History!
Ohno put ideas into practice systematically
When bombarded with questions from our group on
what inspired his thinking, Ohno just laughed and said
he learned it all from Henry Ford's book."
Elimination of Waste
Muda
Materials
Inventory
Time
Transportation
Elimination of Waste
1. 5S
2. Group technology
3. Quality at the source
4. JIT production
5. Kanban production control system
6. Minimized setup times
7. Uniform plant loading
8. Focused factory networks
10
Minimizing Waste 5S
Good factories develop beginning with the 5Ss.
Bad factories fall apart beginning with the 5 Ss.
- Hirouki Hirano
Japanese
Seiri
Seiton
Seiso
Seiketsu
Shitsuke
Translation
Proper arrangement
Orderliness
Cleanliness
Cleanup
Discipline
English
Sort
Simplify
Sweep
Standardize
Sustain
Minimizing Waste 5S
A place for everything and everything in its place
Not just a housekeeping issue
Critical foundation for
Setup reduction
Pull systems
Maintenance
Inventory management
Saw
Saw
Grinder
Grinder
Heat Treat
Lathe
Lathe
Lathe
Press
Press
Press
Lathe
Lathe
Press
Lathe
Press
Heat Treat
Grinder
Saw
Lathe
???
Pros
Cons
Minimal inventory
Requires discipline
Less space
More visual
Paperwork
backlog
Vendor
delinquencies Change
orders
Engineering design
redundancies
Inspection
backlogs
16
Design
backlogs
Decision
backlogs
Jidoka
Uniform
Jan. Units
Feb. Units
Mar. Units
Total
1,200
4,300
9,000
Jan. Units
3,500
or
Feb. Units
Mar. Units
Total
3,000
3,000
3,000
9,000
How
help
save
labor
costs?
Howdoes
doesthe
theuniform
uniformloading
loading
help
save
labor
costs?
21
Minimizing Waste
Focused Factory
Networks
Coordination
System Integration
These
Theseare
aresmall
smallspecialized
specialized
plants
plantsthat
thatlimit
limitthe
therange
rangeof
of
products
productsproduced
produced
(sometimes
(sometimesonly
onlyone
onetype
typeof
of
product
productfor
foran
anentire
entirefacility)
facility)
Keiretsu
TPS 4 Rules
1.
2.
3.
4.
Lean Implementation
Total Quality
Management
Product
Design
Flow
Process
Continual Inventory
Reduction
Empowered Workforce
Problem Solving
Performance Measurement
Involved
Suppliers
Stable
Schedule
Kanban
Pull