[精选]JITDemand-PullLogic(英文版).pptx

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1、JITISQA459MelliePullman1Just-In-Time JITDefinedJIT canbedefinedasanintegratedsetofactivitiesdesignedtoachievehigh-volumeproductionusingminimalinventoriesrawmaterials,workinprocess,andfinishedgoods.JITalsoinvolvestheeliminationofwasteinproductioneffort.JITalsoinvolvesthetimingofproductionresourcese.g

2、.,partsarriveatthenextworkstation“justintime.2The Japanese Approach to ProductivityEliminationofwasteEffortsconcentratedonshopfloorRespectforpeopleQualityimprovementfocus3Waste in Operations1Wastefromoverproduction2Wasteofwaitingtime3Transportationwaste4Inventorywaste5Processingwaste6Wasteofmotion7W

3、astefromproductdefects4JIT Demand-Pull LogicCustomersSubSubFabFabFabFabVendorVendorVendorVendorFinal Assembly5Minimizing Waste:Focused Factory NetworksFinal AssemblyCoordinationSystem Integration6Traditional ConveyanceABCACBSporadic and Infrequent Deliveries from Individual Suppliers7Mixed-Load Deli

4、veryABCABCRegular and Frequent Deliveries from Many Suppliers8Minimizing Waste:Group Technology UsingDepartmental Specializationforplantlayoutcancausealotofunnecessarymaterialmovement.SawSawLathePressPressGrinderLatheLatheSawPressHeat TreatGrinder9Minimizing Waste:Group Technology RevisingbyusingGro

5、up Technology Cellscanreducemovementandimproveproductflow.PressLatheGrinderGrinderA2BSawHeat TreatLatheSawLathePressLathe110Minimizing Waste:Uniform Plant LoadingNot uniformJan.UnitsFeb.UnitsMar.UnitsTotal1,2003,5004,3009,000UniformJan.UnitsFeb.UnitsMar.UnitsTotal3,0003,0003,0009,000Supposeweoperate

6、aproductionplantthatproducesasingleproduct.Thescheduleofproductionforthisproductcouldbeacplishedusingeitherofthetwoplantloadingschedulesbelow.Howdoestheuniformloadinghelpsavelaborcosts?or 11Mixed Batch Examplepanyproducesthreeproductswithamixedmodelassemblyline.Operates16hoursperdayfor250days/yr.Det

7、erminethemixedmodelMPSforadailybatch.DetermineminimumbatchMPSandthemixscheduleforaday.ProductsForecastsyear120,000210,00035,00012Calculations#1#2#3YearForecast20000100005000DailyBatchdivideby250804020HourlyBatchdivideby1652.51.25MinimumBatchMPS421For every unit of#3 minimum batch,we need twice as ma

8、ny#2 and 4 timesAs many#1 so for minimum batch:Produce during each day produce#1,1,1,1,2,2,3-repeated 20 times13Mixed Batch Examplepanyproducesfourproductswithamixedmodelassemblyline.Operates8hoursperdayfor250days/yr.DeterminethemixedmodelMPSforadailyandhourlybatch.Determinemixscheduleforaday.Produc

9、tsForecastsyearI500II1500III4500IV600014Minimizing Waste:Just-In-Time Production Managementphilosophy“Pull”systemthoughtheplantWHATITIS EmployeeparticipationIndustrialengineering/basicsContinuingimprovementTotalqualitycontrolSmalllotsizesWHATITREQUIRES AttackswasteExposesproblemsandbottlenecksAchiev

10、esstreamlinedproductionWHATITDOES StableenvironmentWHATITASSUMES15Minimizing Waste:Inventory Hides ProblemsWork inprocess queues(banks)ChangeordersEngineering designredundanciesVendordelinquenciesScrapDesignbacklogsMachine downtimeDecisionbacklogsInspectionbacklogsPaperworkbacklogExample:Byidentifyi

11、ngdefectiveitemsfromavendorearlyintheproductionprocessthedownstreamworkissaved.Example:Byidentifyingdefectiveworkbyemployeesupstream,thedownstreamworkissaved.16Minimizing Waste:Kanban Production Control SystemsStoragePartAStoragePartAMachineCenterAssemblyLineMaterialFlowCardsignalFlowWithdrawalkanba

12、nProductionkanban17Determining the Number of Kanbans NeededSettingupakanbansystemrequiresdeterminingthenumberofkanbansorcontainersneeded.Eachcontainerrepresentstheminimumproductionlotsize.Anaccurateestimateoftheleadtimerequiredtoproduceacontaineriskeytodetermininghowmanykanbansarerequired.18The Numb

13、er of Kanban Card Setsk=Numberofkanbancardsetsasetisacardd=AveragenumberofunitsdemandedoversometimeperiodL=leadtimetoreplenishanordersameunitsoftimeasdemandS=SafetystockexpressedasapercentageofdemandduringleadtimeC=Containersize 19Example of Kanban Card Determination:Problem DataAswitchassemblyisass

14、embledinbatchesof4unitsfroman“upstreamassemblyareaanddeliveredinaspecialcontainertoa“downstreamcontrol-panelassemblyoperation.Thecontrol-panelassemblyarearequires5switchassembliesperhour.Theswitchassemblyareacanproduceacontainerofswitchassembliesin2hours.Safetystockhasbeensetat10%ofneededinventory.2

15、0Example of Kanban Card Determination:CalculationsAlways round up!21JIT Requirements:Design Flow ProcessLinkoperationsBalanceworkstationcapacitiesRe-layoutforflowEmphasizepreventivemaintenanceReducelotsizesReducesetup/changeovertime22JIT Requirements:Improve Product DesignStandardproductconfiguratio

16、nStandardizeandreducenumberofpartsProcessdesignwithproductdesignQualityexpectations23Respect for PeopleLevelpayrollsCooperativeemployeeunionsSubcontractornetworksInvertedpyramidmanagementstyleSmallgroupinvolvementactivities24JIT Requirements:Total Quality ControlWorkerresponsibilityMeasureSQCEnforce

17、plianceFail-safePoke-yokemethodsAutomaticinspection25POKE-YOKEs address MistakesDamagedpartsMissingpartsReversedpartsWrongpartsWrongsizeorshapeWrongchemicalpropertiesWrongphysicalpropertiesWrongitemshippedWronglabelWrongpackageDamagedfinishedproductOmittingapartOmittingaprocessPerformingaprocessinco

18、rrectlyPerformingaprocessonthewrongpartPerformingaprocessinimproperenvironmentalconditionsPerformingthewrongprocessSettingupequipmentincorrectlySettingupaworkpieceincorrectlyAdjustingequipmentincorrectlyToolingsetupincorrectlyToolingadjustedincorrectlyInstallingwrongpartInstallingpartincorrectlyDEFE

19、CTSDEFECTSMISTAKESMISTAKES26JIT Requirements:Work with VendorsReduceleadtimesFrequentdeliveriesProjectusagerequirementsQualityexpectations27JIT Requirements:Reduce Inventory MoreLookforotherareaswhereinventoryhidesStoresTransitCarouselsConveyors28MRP and JITMRP is a planning system that does not do

20、detailed shop floor schedulingMRP requires fixed lead times which might actually vary with batch sizeJIT excels at rapidly moving small batches of material through the system29MRP Small Bucket Approach1.1.MRP“bucketsMRP“buckets are reduced to daily or hourly are reduced to daily or hourly The most m

21、on planning period The most mon planning period time buckettime bucket for MRP systems is weeklyfor MRP systems is weekly2.2.Planned receipts are used internally to sequence Planned receipts are used internally to sequence productionproduction3.3.Inventory is moved through the plant on a JIT Invento

22、ry is moved through the plant on a JIT basisbasis4.4.pleted products are moved to finished goods pleted products are moved to finished goods inventory which reduces required quantities for inventory which reduces required quantities for subsequent planned orderssubsequent planned orders Back flushin

23、g based on the BOM is used to Back flushing based on the BOM is used to deduct inventory that was used in productiondeduct inventory that was used in production30MRP Balanced FlowUsed in repetitive operationsMRP plans are executed using JIT techniques based on“pull principlesFlows are carefully bala

24、nced with small lot sizes31MRP vs.The SupermarketItems used by many products are held in a mon area often called a supermarketItems are withdrawn as neededInventory is maintained using JIT systems and procedures mon items are not planned by the MRP system329、静夜四无邻，荒居旧业贫。11月-2311月-23Sunday,November 2

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