[精选]CharacteristicsofJITEnvironment(英文版).pptx

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1、JITHistory This texts idea Philosophical change Taiichi Ohno Toyota Just-in-Time manufacturing is the elimination of all waste and continuous improvement of productivity Waste means anything other than the minimum amount of equipment,parts,space,material,and workers time absolutely necessary to add

2、value to the product.JIT The long-term result of eliminating waste is a cost-efficient,quality-oriented,fast-response organization that is responsive to customer needs Adding value to a product does not mean adding cost.Users are not concerned with the manufacturers cost but only with the price they

3、 must pay and the value they receive.Many activities increase cost without adding value and,as much as possible,these activities should be eliminated.Waste Anything in the product cycle that does not add value to the product is waste Management is responsible for establishing policies for the market

4、 segments the pany wishes to serve and for deciding how broad or specialized the product line is to be.Standardization Standardization reduces the planning and control effort needed,the number of items required,and the inventory that has to be carried.The“ideal product is one that meets or exceeds c

5、ustomer expectations,makes the best use of material,and can be manufactured with a minimum of waste Waste in Manufacturing Toyota identified seven important sources of waste in manufacturing.The first four relate to the design of the manufacturing system and the last three to the operations and mana

6、gement of the system:1 The process Consistent,minimum scrap,least cost 2 Methods-wasted movement,time and effort.ie tools 3 Movement storing ponents 4 Product defects rework,bad quality customer 5 Waiting time worker and/or material 6 Overproduction excess inventory 7 Inventory-excessInventories rol

7、e in JIT Batch of 1000 parts Quality Rework Slows CIP Batch 100 Increased responsiveness Less inspection Better qualityCh 15-6 2000 by Prentice-Hall IncRussell/Taylor Oper Mgt 3/eStandard Operating RoutineCharacteristics of JIT Environment Flow manufacturing-only certain items Cellular manufacturing

8、 functional layout and work cell layout Process flexibility worker and machine flexibility.Quick changeover shorten setups Reduced EOQ,queue,MLT,WIP Improved quality and process flowCh 15-8 2000 by Prentice-Hall IncRussell/Taylor Oper Mgt 3/eManufacturing Cell With Worker RoutesEnterWorker 1Worker 2

9、Worker 3ExitKey:Product routeWorker routeMachinesTQM Quality is important for two reasons.If quality is not present in what is supplied to the customer and the product is defective,the customer will be dissatisfied.If a process produces scrap,it creates disrupted schedules that delay supplying the c

10、ustomer,increases the cost of the product.Manufacturing must ensure that the process is capable of producing the required quality consistently and with as close to zero defects as possible.The benefits of a good quality program are less scrap,less rework,less inventory,better on-time production,time

11、ly deliveries,and more satisfied customers.Total productive maintenance is“preventive maintenance plus continuing efforts to adapt,modify,and refine equipment to increase flexibility,reduce material handling,and promote continuous flow.Uniform plant loading means that the work done at each workstati

12、on should take about the same time.Balancing the line,which means that the time taken to perform tasks at each workstation on the line is the same or very nearly so.The result will be no bottlenecks and no buildup of work-in-process inventory.Pull system Starts at the end of the line and pulls produ

13、ct from the preceding operation as needed.The preceding operation does not produce anything unless a signal is sent from the following operation to do so.The system for signaling demand depends on the physical layout and conditions in the plant.The most well known system is the Kanban system.The det

14、ails vary,but it is basically a two-bin,fixed-order-quantity,order-point system Valid schedule The schedule sets the flow of materials ing into the factory and the flow of work through manufacturing.To maintain an even flow,the schedule must be level.In other words,the same amount should be produced

15、 each day.Mixed-model scheduling Means that some of everything is made each day in the proportions to meet demand.If demand shifts between models,the assembly line can respond daily.Week OnHand1 2 3Economy 0 1500Standard 600 1500 300Deluxe 800 1200Total 1400 1500 1500 1500Week OnHand1 2 3Economy 250

16、 500 500 500Standard 300 600 600 600Deluxe 200 400 400 400Total 750 1500 1500 1500Master Production Schedule Leveled Master Production Schedule Linearity is achieving the plan no more,no less and is usually reached by scheduling to less than full capacity.Supplier Partnerships.Trust Long-term mitmen

17、t Shared visionTotal Employee Involvement A successful JIT environment can be achieved only with the cooperation and involvement of everyone in the organization Operators must take responsibility for improving processes,controlling equipment,correcting deviations,and be ing vehicles for continuous i

18、mprovement.Employees must be flexible in the tasks they do.In a JIT environment,more emphasis is placed on the leadership role.Managers and supervisors must be e coaches and trainers,develop the capability of employees,and provide coordination and leadership for improvements.Effects of MPC in JIT En

19、vironment Forecasting-is shortened lead-time.PP Supplier relationships,improved material flow.MPS see slide 14 Shorter lead-times reduce time fences,greater customer service and closer to make to order environment.MRP reduction to daily time buckets No inventory,no netting and sometimes no offsettin

20、g BOMS are flattened or simplified Capacity leveled Inventory management increase transactions,backflushing/post deduct.The Pull System MRP is a push system,meaning that the material needs are calculated ahead of time and pushed out to the production systems as a production order.The pull system und

21、erlying concept is not to preplan and generate schedules,but to react to the final customer order and produce only what is needed to satisfy demand and them only when it is needed.Cal Berkeley VideoCh 15-10 2000 by Prentice-Hall IncRussell/Taylor Oper Mgt 3/eKanban Production Control System Kanban c

22、ard indicates standard quantity of production Derived from two-bin inventory system Kanban maintains discipline of pull production Production kanban authorizes production Withdrawal kanban authorizes movement of goodsCh 15-11 2000 by Prentice-Hall IncRussell/Taylor Oper Mgt 3/eA Sample KanbanMachini

23、ngM-2AssemblyA-4Part no.:7412Description:Slip ringsFrom:To:Box capacity 25Box Type AIssue No.3/5Ch 15-22 2000 by Prentice-Hall IncRussell/Taylor Oper Mgt 3/eInventory Hides ProblemsPoor QualityUnreliableSupplierMachineBreakdownInefficientLayoutBadDesignLengthySetupsCh 15-23 2000 by Prentice-Hall Inc

24、Russell/Taylor Oper Mgt 3/eLower Levels Of Inventory To Expose ProblemsPoor QualityUnreliableSupplierMachineBreakdownInefficientLayoutBadDesignLengthySetupsWhich to Choose MRP ERP,Kanban,or Theory of Constraints?Because of the forward-looking nature of MRP,it can be very effective in an environment

25、with a great deal of variability and uncertainty.MRPs major disadvantage is that it is highly data dependent,both accurate and timely.JIT and Kanban work best in a highly stable and predictable environment.They are not as effective in highly volatile environments.Theory of Constraints TOC works best

26、 when the constraint can be identified and will be a constraint long enough to be managed effectively.TOC is not as effective in a less stable environment where the constraint changes and not easily identified.Hybrid systems like Kanban and MRP are successful when MRP is used for advanced planning a

27、nd Kanban is used as an execution system.JIT and TOC can be use together where TOC prioritizes the areas of improvement based on knowing the constraints and the JIT continuous improvement efforts follow that lead.Non JIT Situations Where the demand pattern is unstable Where custom engineering is req

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