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Lean Production

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Title: Lean Production


1
Chapter 12
Lean Production Just-in-Time
JIT Defined The Toyota Production System JIT
Implementation Requirements JIT in Services
2
Just-in-Time (JIT)
  • JIT is a philosophy of operations management that
    seeks to eliminate waste in all aspects of a
    firms production activities
  • (also called Lean Production)
  • JIT relies on a pull system.
  • Supplies and components are pulled through
    system to arrive where they are needed when they
    are needed.

3
Waste in Operations
  • Waste from overproduction
  • Waste of waiting time
  • Transportation waste
  • Inventory waste
  • Processing waste
  • Waste of motion
  • Waste from product defects

4
Elements of Waste Reduction
  • Minimize waste thru
  • Focused Factory Networks
  • Flow Lines, based on Group Technology
  • Quality at the Source
  • Uniform Plant Loading
  • Minimized Setup Times and Small Lot Sizes
  • JIT production
  • Pull System, using Kanban

5
Push versus Pull Systems
  • Push system material is pushed into downstream
    workstations by the schedule, regardless of
    whether it is needed.
  • Pull system material is pulled to a workstation
    by a signal (kanban) from the user to the
    supplier, just as it is needed.

6
JIT Demand-Pull Logic
The customer starts the process, pulling an
inventory item from Final Assembly
Then sub-assembly work is pulled forward by that
demand
The process continues throughout the entire
production process and supply chain
7
Kanban
  • Japanese word for card
  • Pronounced kahn-bahn (not can-ban)
  • Downstream operations authorize more production
  • Material is pulled through the operations by a
    signal from the user to the supplier
  • Reduces Inventory (queue limitation)

8
Inventory Waste Reduction I
Inventory level (hides problems)
Capacity Imbalances
Unreliable Vendors
Scrap
9
Inventory Waste Reduction II
Reducing inventory revealsproblems so they can
be solved.
Unreliable Vendors
Capacity Imbalances
Scrap
10
Implementing JIT
  • Design a Flow Process
  • Use Total Quality Control
  • Stabilize the Schedule
  • Install a Pull System-Kanban
  • Work with Vendors
  • Reduce Inventory more
  • Improve Product Design

11
End of Chapter 12
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