JUST IN TIME oleh consultant AQD - ICA

Pull Manufacturing
Kanban, Just in Time, Demand Flow
By Tim Management Support

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


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

Kanban Production Control Systems
TAKT Time Example
 Net Available Operating Time
• Time per shift 480´ (minutes)
• Breaks (2 @ 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"

 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?