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IENG 451

IENG 451. JIT. Production Physics. Little’s Law Throughput = WIP/Cycle time For fixed capacity, cycle time and WIP or proportional – thus you can increase throughput either by increasing WIP or by decreasing cycle time . Production Physics.

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IENG 451

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  1. IENG 451 JIT

  2. Production Physics • Little’s Law Throughput = WIP/Cycle time • For fixed capacity, cycle time and WIP or proportional – thus you can increase throughput either by increasing WIP or by decreasing cycle time

  3. Production Physics • Law of variability – increasing variability inevitably degrades the performance of the system • Law of variability buffering – variability in a production system will be buffered by some combination of inventory, capacity, or time

  4. JIT Principles • Don’t produce something unless a customer has ordered it • Level demand so that work may proceed smoothly throughout the plant • Link all processes to customer demands through visual tools (kanbans) • Maximize the flexibility of people and machinery

  5. Pull Systems • Nobody upstream produces a good or a service until somebody downstream asks for it

  6. Pull Systems • Nobody upstream produces a good or a service until somebody downstream asks for it

  7. Pull Systems • Nobody upstream produces a good or a service until somebody downstream asks for it

  8. Kanban Rules • Never ship defective items • Customer withdraws only what is needed • Produce only quantity withdrawn by the customer • Level production • Use kanban to fine-tune production • Stabilize and strengthen the process

  9. Production orders • Batch of 10 vs Batch of 100 • Adjust more quickly to demand • Better sense of takt time • Fewer peaks and valleys • Better control of abnormality production

  10. Pull Systems • Type A • Frequent orders with short lead times, most common, replenishing gaps created in the finished goods storage • Type B • Infrequent orders or long lead times, pacemaker is usually midstream • Type C • Combination of type A and type B running in parallel

  11. Value Stream Mapping • VSM helps grasp current condition and identify improvement opportunities

  12. VSM Steps • Determine the individual product or service you will map • Draw the process flow

  13. VSM Steps • Add material flow

  14. VSM Steps • Add Information flow

  15. VSM Steps • Collect process data and connect it to boxes on chart • Add process and lead times

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