Beruflich Dokumente
Kultur Dokumente
Sardjono
Session 13
Lean Production (JIT Concept)
Irwin/McGraw-Hill
20 - 2
Objectives
Waste of Operation
Respect for the People Lean Services
Irwin/McGraw-Hill
20 - 3
Lean Production
Defined
Lean Production can be defined as an integrated set of activities designed to achieve high-volume production using minimal inventories (raw materials, work in process, and finished goods) Lean Production also involves the elimination of waste in production effort Lean Production also involves the timing of production resources (i.e., parts arrive at the next workstation just in time)
Irwin/McGraw-Hill
20 - 4
PRODUCTION SYSTEM
Based on two philosophies:
A) Elimination of waste
Irwin/McGraw-Hill
20 - 5
A) Waste in Operations
1.
2.
3.
4.
5. 6. 7.
Inventory waste
Processing waste Waste of motion Waste from product defects
The McGraw-Hill Companies, Inc. 2009
Irwin/McGraw-Hill
Elimination of Waste
1. 2. 3. 4. 5.
6.
7.
Irwin/McGraw-Hill
Irwin/McGraw-Hill
20 - 8
Irwin/McGraw-Hill
20 - 9
Irwin/McGraw-Hill
Withdrawal kanban
This puts the system back were it was before the item was pulled
Machine Center
Storage Part A
Storage Part A
Assembly Line
Production kanban
The process begins by the Assembly Line people pulling Part A from Storage
Irwin/McGraw-Hill
Setting up a kanban system requires determining the number of kanbans cards (or containers) needed Each container represents the minimum production lot size An accurate estimate of the lead time required to produce a container is key to determining how many kanbans are required
Irwin/McGraw-Hill
A switch assembly is assembled in batches of 4 units from an upstream assembly area and delivered in a special container to a downstream control-panel assembly operation The control-panel assembly area requires 5 switch assemblies per hour The switch assembly area can produce a container of switch assemblies in 2 hours Safety stock has been set at 10% of needed inventory
The McGraw-Hill Companies, Inc. 2009
Irwin/McGraw-Hill
20 - 15
Irwin/McGraw-Hill
20 - 16
Level payrolls Cooperative employee unions Subcontractor networks Bottom-round management style
Irwin/McGraw-Hill
20 - 17
Irwin/McGraw-Hill
20 - 18
Irwin/McGraw-Hill