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Kohler Operating System. Lean Manufacturing. Lean Manufacturing Customer Order Driven (Pulled) One-piece Processing Near-Zero, Idle Inventory Quality Problems are Surfaced. Traditional Manufacturing Planned and Scheduled (Pushed) Batch Processing Extensive Idle Inventory
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Kohler Operating System Lean Manufacturing
LeanManufacturing Customer Order Driven (Pulled) One-piece Processing Near-Zero, Idle Inventory Quality Problems are Surfaced Traditional Manufacturing Planned and Scheduled (Pushed) Batch Processing Extensive Idle Inventory Quality Problems are Hidden vs
TIME PRE R&D A/R MFG DIST PLAN PRE R&D A/R MFG DIST PLAN Time — Source of Competitiveness
Lead Time Definition The amount of time it takes to convert raw material into finished goods and ship them to the customer. The elimination of waste will reduce lead-time which has a favorable affect on safety, quality, delivery, cost and productivity.
Order Problems/Waste Excess Inventory Problems/Waste Problems/Waste Long Lead Time Excess Inventory Delivery Lead Time Is Affected by Flow
TIME Raw Material Finished Goods = Value Added (VA) Time = Non-Value Added (NVA) Time Product Lead Time
Extra Inventory Extra Defects WASTE OF OVERPRODUCTION Extra Space Extra Handling Extra Machinery Extra Paperwork Extra Overhead
Sea of Inventory Line Long Lack of Balance Communication Transportation Housekeeping Problems Poor Scheduling Long Setup Quality Time Supplier Absenteeism Problems Machine Delivery Breakdown Excess Inventory Hides Problems
Reducing Excess Inventory . . . . . . . . Exposes Problems Raw Material Finished Product to Customer Sea of Inventory Line Long Lack of Communication Balance Transportation Housekeeping Problems Poor Scheduling Long Setup Quality Time Supplier Absenteeism Problems Machine Delivery Breakdown
KOHLER Just-in-Time (JIT) Mfg. Producing just what is needed, when it is needed, in the amount needed, with only the minimum required materials, equipment, labor, and space.
“Push” vs. “Pull” Material Flow Using an MRP system or other mechanism, work is scheduled and pushed through each stage in the production process in order to meet specified delivery dates for finished products. Push Work at each stage in the production process is pulled through the system by actual demand for final products. Pull THINK:“Bucket Brigade…”
JIT Production? Pull Systems? Kanban? … How does it all relate? • “Kanban” • Means “card” in Japanese • It is a “pull” production system and used as the means of production control in JIT • How kanbans work: • When an order to produce a finished product is issued to the plant, workers withdraw components from a “standard container” and build the product. • Each container has a kanban on it, which is sent to the upstream as an authorization to produce. • This in turn activates kanbans at that operation, sent to the next operation upstream, and so on. The process goes all the way to kanbans issued to the vendor to produce and/or ship. • Computer control is unnecessary:
Seeing JIT/Kanban at Work Work Center 1
Seeing JIT/Kanban at Work Work Center 1 Work Center 2
Seeing JIT/Kanban at Work Work Center 1 Work Center 2 Work Center 3
Seeing JIT/Kanban at Work Container to be worked on
Seeing JIT/Kanban at Work Flag or signal marker
Seeing JIT/Kanban at Work Start Simulation(Any Questions?)
Seeing JIT/Kanban at Work Puts flag on post
Seeing JIT/Kanban at Work Puts flag on post
Seeing JIT/Kanban at Work What happens next?
