Just-In-Time Manufacturing Systems: (WEEK 11)
Just-In-Time Manufacturing Systems: (WEEK 11)
Just-In-Time Manufacturing Systems: (WEEK 11)
JUST-IN-TIME
MANUFACTURING SYSTEMS
[WEEK 11]
Assistant Professor Dr. Erkan Gunpinar
Company
Just-in-time approach
Terms of TPS
Autonomation: manual or automatic stopping of
Muda
A Japanese word
Meaning waste
kaisendon
Types of muda
Muda for correction: rework process
Muda for overproduction
Muda in conveyance
Muda for inventory
Muda of motion: unnecessary movement of workers,
materials.
Muda for waiting
problems.
Too much loading of machines breakdowns and
defects.
Push System
Work orders push materials to the manufacturing floor to
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Pull System
There is always feedback from the subsequent to the
preceding stages.
MPS only is used for deciding approximate resource
requirements of workstations.
Materials move in the same direction as in a push system,
build schedules (information) travel in the opposite
direction.
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Cont.
A kanban system is used to communicate the schedule
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Kanban
Kanban () = visible record
Uses simple visual signals to control production pull
processing
A set of cards that travel between preceding and subsequent
processes.
Contains all information
needed to communicate
a production order or a
delivery order
One kanban per bin of
parts
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Kanban example
Workcenter B uses parts produced by Workcenter A.
Workcenter B
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Workcenter B
Kanban Card
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Workcenter B
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DT(1 x)
y
C
y
D
T
C
x
=
=
=
=
=
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Example
Hourly demand = 300 units
5 kanban cards
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Types of kanbans
Withdrawal (conveyance) kanban: pass the authorization
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Production kanban
Release an order to build parts equal to the lot size
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collection box
3. Once all the parts in the container are consumed at
SPS2, attach a withdrawal kanban from the collection
box to the empty container. Move it to P3.
4. a) Detach the withdrawal kanban from the empty
container, b) attach it to a full parts container. c) Remove
the production kanban from the container to be sent to
SPS2. d) send the kanban to PPS1 to trigger the new
production. x) empty container is sent to PPS1.
5. Put all the produced parts in the empty container and
send it to SA with the production kanban.
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Flow diagram
c, d
a, b
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needed.
Do not send defective parts to the subsequent process.
The preceding process should produce only the exact
quantity of parts withdrawn by the subsequent process.
Minimize the fluctuations of production.
Tuning of production using kanban.
(stopping the process if requirements decrease)
(using overtime if requirements increase)
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Final
assembly
Finished
goods
Work
cell
Kanban
Kanban
Kanban
Customer
order
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Signal kanban
Previous implementation of JIT with kanbans is for the
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container
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Just-in-time purchasing
Purchase lot size: purchasing in small quantities with
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major problems.
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Benefits of JIT
Increased productivity
Better quality
Reduced lead times
Less scrap and rework
Less WIP (work in process)
Higher worker motivation and increased teamwork
Saved space
Increased worker and equipment efficiency
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2.
3.
4.
5.
6.
7.
8.
9.
machine run
Waiting for parts
Counting parts
Overproduction
Moving parts over
long distance
Storing inventory
Looking for tools
Machine
breakdowns
Rework