Pull Manufacturing Kanban, Just in Time, Demand Flow http:www'managementsupport'com

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Pull ManufacturingKanban, Just in Time, Demand
Flow http//www.managementsupport.com
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Outline

• Why Pull Manufacturing?
• The Problem of Inventory
• Just In Time
• Kanban
• One Piece Flow
• Demand / Pull
• Standard Work Takt Time
• Production Smoothing

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JIT Tactics

• Single Minute Exchange of Dies (SMED)
• Statistical Process Control
• Use of standard containers
• Doable stable schedules with adequate visibility
• TAKT-Time
• 5-S Program
• Kaizen Event

• Visual control
• Flexible workers
• Tools at the point of need
• Product redesign
• Group Technology
• Total Productive Maintenance

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Kanban Production Control Systems
Production Kanban
Withdrawal Kanban
A
Machine Center
Assembly Line
B
Storage
....
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TAKT Time Example

• Net Available Operating Time
• Time per shift 480 (minutes)
• Breaks (2 _at_ 10) - 20
• Clean-up - 20
• Lunch - 30
• NAOT/shift 410
• Customer Requirements
• Monthly 26,000 units/month
• No. Working Days 20 days/month
• CR/Day 1,300
  units/day
• TAKT Time
• 410 x 60 x 3 shifts (73,800) divided
  by 1,300
• 57.769 seconds per part or 57"

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Production Smoothing / Leveling

• Averaging both the volume and the production
  sequence of different model types on a
  mixed-model production line
• Example Toyota Manufacturing
• Toyota makes 3 car models - a convertible,
  hardtop, and an SUV. Assume that customers are
  buying nine convertibles, nine hardtops, and nine
  SUVs each day. What is the most-efficient way to
  make those cars?