Pull Sample

Pull Manufacturing and Just In Time Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams

Contents • • • •

Introduction Background and History Components and Implementation Knowledge Check

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Introduction • Just In Time (JIT) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and cycle time. The process is driven by a series of signals, or Kanban, that tell production processes to make the next part. When implemented correctly, JIT can lead to dramatic improvements in a manufacturing organization's return on investment, quality, and efficiency.

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Components and Implementation • Pull vs. Push Scheduling • The Problem of Inventory • Just In Time – Principles – Benefits and Limitations

• Implementing JIT – – – – – –

Kanban Pull Systems Quality One Piece Flow Continuous Flow Takt Time

• JIT and Suppliers © 2007 Superfactory™. All Rights Reserved.

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Push Vs. Pull Scheduling • Push Scheduling – traditional approach – “move the job on when finished” – problems - creates excessive inventory

• Pull scheduling – coordinated production – driven by demand (pulled through system) – extensive use of visual triggers (production/withdrawal kanbans)

© 2007 Superfactory™. All Rights Reserved.

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Inventory Hides Problems

Work in process inventory level (hides problems) Unreliable Vendors

Scrap

Capacity Imbalances

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The Philosophy of JIT • JIT means getting the right quantity of goods at the right place and the right time • Often termed “Lean Systems” • All waste must be eliminated- non value • items Broad view that entire organization must focus on serving customers • JIT is built on simplicity- the simpler the • better Focuses on improving every operation• Kaizen Install simple visible control systems • Flexibility to produce different models/features © 2007 Superfactory™. All Rights Reserved.

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Elements of JIT Manufacturing • JIT Manufacturing is a philosophy of value-added manufacturing • Achieved by – – – – – –

Inventory reduction - exposes problems Kanbans & pull production systems Small lots & quick setups Uniform plant loading Flexible resources Efficient facility layouts

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JIT Tactics • • • • • • • • • • • • •

Single Minute Exchange of Dies (SMED) Statistical Process Control Use of standard containers Doable stable schedules with adequate TAKT-Time visibility 5-S Program Kaizen Event Visual control Flexible workers Tools at the point of need Product redesign Group Technology Total Productive Maintenance © 2007 Superfactory™. All Rights Reserved.

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JIT and Suppliers • • • •

Few Nearby (if possible) Repeat business/Longer Term Agreements Analysis to enable desirable suppliers to become or stay price competitive • JIT Logistics: – – – –

Frequent Deliveries/Smaller Quantities Exact Quantities Consumption initiates deliveries Deliveries directly to the point of use

• Perfect Parts • Concurrent engineering design practices © 2007 Superfactory™. All Rights Reserved.

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