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Pull Manufacturing Kanban, Just in Time, Demand Flow. Lean Manufacturing Series. Outline. Why Pull Manufacturing? The Problem of Inventory Just In Time Kanban One Piece Flow Demand / Pull Standard Work & Takt Time Production Smoothing. JIT Tactics.
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Pull ManufacturingKanban, Just in Time, Demand Flow Lean Manufacturing Series
Outline • Why Pull Manufacturing? • The Problem of Inventory • Just In Time • Kanban • One Piece Flow • Demand / Pull • Standard Work & Takt Time • Production Smoothing
JIT Tactics • Single Minute Exchange of Dies (SMED) • Statistical Process Control • Use of standard containers • Doable stable schedules with adequate visibility • TAKT-Time • 5-S Program • Kaizen Event • Visual control • Flexible workers • Tools at the point of need • Product redesign • Group Technology • Total Productive Maintenance
Kanban Production Control Systems Production Kanban Withdrawal Kanban A Machine Center Assembly Line B Storage ....
TAKT Time Example • Net Available Operating Time • Time per shift 480´ (minutes) • Breaks (2 @ 10´) - 20´ • Clean-up - 20’ • Lunch - 30’ • NAOT/shift 410´ • Customer Requirements • Monthly 26,000 units/month • No. Working Days 20 days/month • CR/Day 1,300 units/day • TAKT Time • 410’ x 60” x 3 shifts (73,800) divided by 1,300 • 57.769 seconds per part or 57"
Production Smoothing / Leveling • Averaging both the volume and the production sequence of different model types on a mixed-model production line • Example: Toyota Manufacturing • Toyota makes 3 car models - a convertible, hardtop, and an SUV. Assume that customers are buying nine convertibles, nine hardtops, and nine SUVs each day. What is the most-efficient way to make those cars?