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Презентация на тему Just in time & lean manufacturing. Chapter 15

Just In TimeJust in Time (JIT) – a Business PhilosophyProduction system: manufacturing & movement of materials and goods occur just when they are needed, usually in small batchesJIT operates with very little “fat” (waste)Defines waste in
CHAPTER 15:Just in Time & Lean Manufacturing Just In TimeJust in Time (JIT) – a Business PhilosophyProduction system: manufacturing Sources of Waste: Waiting WC 10WC 20WC 30After finished in WC 10 JIT WastesOverproduction – making more than we can sell nowWaiting time – JIT Goals and Building Blocks Production FlexibilityReduce downtime by reducing change-over timeUse preventive maintenance to reduce unexpected LEAN Manufacturing Product DesignStandardized partsModular designQualityDFM (Design for Manufacturing) Mistake-proofing design Process DesignSmaller production lot sizesSetup time reductionManufacturing cellsQuality improvements –preventive actions Reduced inventory Work CellsExamples Benefits of Small Lot Sizes Small batch sizes and changing product mixes require frequent machine setupsWorkers are Prevent Defects from occurring using:Six Sigma to reduce process variabilityPoka Yoke to Personnel/Organizational ElementsWorkers as assetsCross-trained workersTrain workers in problem-solvingForm work cell teams Manufacturing Planning and ControlLevel loading – keep consistent amount of production Example Visual Controls Pull/Push Systems and KanbanPull system: System for moving work where a workstation Push vs. PullBecause of Wastes inherent in a PUSH system we tend Kanban Example Kanban ExamplesTwo bin system – RED means empty – Stores to replenishEmpty means – bring another! Preventive Maintenance and HousekeepingPreventive maintenance Maintaining equipment in good operating condition and Housekeeping: 5S Program. Tool BoardWork StationHousekeeping – 5S Program
Слайды презентации

Слайд 2 Just In Time

Just in Time (JIT) – a

Just In TimeJust in Time (JIT) – a Business PhilosophyProduction system:

Business Philosophy
Production system: manufacturing & movement of materials and

goods occur just when they are needed, usually in small batches
JIT operates with very little “fat” (waste)
Defines waste in terms of customer value
JIT Goals
Eliminate disruptions
Make system flexible by reduce setup and lead times
Eliminate waste, especially excess inventory


Слайд 3 Sources of Waste: Waiting



WC 10
WC 20
WC 30
After

Sources of Waste: Waiting WC 10WC 20WC 30After finished in WC

finished in WC 10 wait to move out of

the WC

Arrive at WC 20 –wait to be worked on

Move

After finished in WC 20 wait to move out of WC

Large Batch sizes impact Wait times!


Слайд 4 JIT Wastes
Overproduction – making more than we can

JIT WastesOverproduction – making more than we can sell nowWaiting time

sell now
Waiting time – for the next process
Unnecessary handling

& transportation
Processing waste
Inefficient work methods
Product defects – producing bad
quality items

Слайд 5 JIT Goals and Building Blocks

JIT Goals and Building Blocks

Слайд 6 Production Flexibility
Reduce downtime by reducing change-over time
Use preventive

Production FlexibilityReduce downtime by reducing change-over timeUse preventive maintenance to reduce

maintenance to reduce unexpected breakdowns
Cross-train workers to help clear

bottlenecks – workers skilled in many different work processes
Reserve capacity for important customers Ex. Operate at 90-95% capacity – is this a good strategy?

Слайд 7




LEAN Manufacturing

LEAN Manufacturing

Слайд 8 Product Design

Standardized parts
Modular design
Quality
DFM (Design for Manufacturing)
Mistake-proofing

Product DesignStandardized partsModular designQualityDFM (Design for Manufacturing) Mistake-proofing design

design


Слайд 9 Process Design
Smaller production lot sizes
Setup time reduction
Manufacturing cells
Quality

Process DesignSmaller production lot sizesSetup time reductionManufacturing cellsQuality improvements –preventive actions Reduced inventory

improvements –preventive actions
Reduced inventory


Слайд 10

Work Cells
Examples

Work CellsExamples

Слайд 11 Benefits of Small Lot Sizes

Benefits of Small Lot Sizes

Слайд 12
Small batch sizes and changing product mixes require

Small batch sizes and changing product mixes require frequent machine setupsWorkers

frequent machine setups

Workers are trained to do their own

setups

Do as much of the set-up external from the manufacturing process

Group Technology may be used to reduce cost and setup time (group similarly-made products)

Setup Time Reductions


Слайд 13
Prevent Defects from occurring using:
Six Sigma to reduce

Prevent Defects from occurring using:Six Sigma to reduce process variabilityPoka Yoke

process variability
Poka Yoke to mistake-proof

Autonomation:
Automatic detection of defects

during production Ex. Laser beams to check fill amounts of bottles

Quality Improvement


Слайд 14 Personnel/Organizational Elements
Workers as assets

Cross-trained workers

Train workers in problem-solving

Form

Personnel/Organizational ElementsWorkers as assetsCross-trained workersTrain workers in problem-solvingForm work cell teams

work cell teams



Слайд 15 Manufacturing Planning and Control
Level loading – keep consistent

Manufacturing Planning and ControlLevel loading – keep consistent amount of production

amount of production Example – always produce batches of

5 pieces
Use Pull Systems and Kanban (card signal system) – automate production control
Close supplier relationships with key suppliers
Visual systems – easy to see problems. Example – green light when machine running, red light when broken down
Preventive maintenance – to reduce unexpected machine breakdowns

Слайд 16

Visual Controls

Visual Controls

Слайд 17 Pull/Push Systems and Kanban
Pull system:
System for moving

Pull/Push Systems and KanbanPull system: System for moving work where a

work where a workstation pulls output from the preceding

station as needed. (e.g. Kanban)
Push system:
System for moving work where output is pushed to the next station as it is completed
Kanban:
Card or other device that communicates demand for work or materials to the preceding station
Kanban: Japanese word meaning “signal” or “visible record”
Paperless production control system
Authority to pull, or produce comes from a downstream process.


Слайд 18 Push vs. Pull






Because of Wastes inherent in a

Push vs. PullBecause of Wastes inherent in a PUSH system we

PUSH system we tend to produce more to offset

waste (including quality)

Слайд 19 Kanban Example





Kanban Example

Слайд 20 Kanban Examples





Two bin system – RED means empty

Kanban ExamplesTwo bin system – RED means empty – Stores to replenishEmpty means – bring another!

– Stores to replenish
Empty means – bring another!


Слайд 21 Preventive Maintenance and Housekeeping
Preventive maintenance
Maintaining equipment in

Preventive Maintenance and HousekeepingPreventive maintenance Maintaining equipment in good operating condition

good operating condition and replacing parts that have a

tendency to fail before they actually do fail

Housekeeping
Maintaining a workplace that is clean and free of unnecessary materials (5S program)
Sort
Straighten
Shine
Standardize
Sustain

Слайд 22 Housekeeping: 5S Program


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Housekeeping: 5S Program.

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