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Lean Systems

Explore characteristics and benefits of Lean Systems with Just-in-Time inventory, small lot sizes, and automated production. Learn about Single-Card Kanban systems and preventive maintenance for consistent quality delivery.

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Lean Systems

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  1. Lean Systems

  2. Pull method of materials flow • Consistently high quality • Small lot sizes • Uniform workstation loads • Standardized components and work methods • Close supplier ties • Flexible workforce • Line flows • Automated production • Preventive maintenance Characteristics of Lean Systems: Just-in-Time

  3. Lot Size and Cycle Inventory

  4. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  5. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  6. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory Lot size = 50 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  7. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory Lot size = 50 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  8. 100 – 75 – 50 – 25 – 0 – Average cycle inventory Lot size = 100 On-hand inventory Lot size = 50 5 10 15 20 25 30 Time (hours) Figure 16.1 Lot Size and Cycle Inventory

  9. Unreliable suppliers Capacity imbalance Scrap Continuous Improvement with Lean Systems Figure 16.2

  10. Single-Card Kanban System

  11. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  12. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  13. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  14. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  15. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  16. Assembly line 1 O2 Fabrication cell O3 O1 Assembly line 2 O2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers Full containers Figure 16.3

  17. Assembly line 1 Assembly line 2 Receiving post Kanban card for product 1 Storage area Kanban card for product 2 Single-Card Kanban System Empty containers O2 Fabrication cell O3 O1 Full containers O2 Figure 16.3

  18. Each container must have a card • Assembly always withdraws from fabrication (pull system) • Containers cannot be moved without a kanban • Containers should contain the same number of parts • Only good parts are passed along • Production should not exceed authorization Part Number: 1234567Z Location: Aisle 5 Bin 47 Lot Quantity: 6 Supplier: WS 83 Customer: WS 116 Single-Card Kanban System KANBAN

  19. Number of Containers

  20. d( w + p )( 1 + a ) c k = d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers Example 16.1

  21. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers 2000( 0.08 + 0.02 )( 1 + 0.10 ) 22 k = Example 16.1

  22. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers 2000( 0.08 + 0.02 )( 1 + 0.10 ) 22 k = Example 16.1

  23. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.08 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers Example 16.1

  24. d( w + p )( 1 + a ) c k = d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers Example 16.1

  25. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers 2000(0.06 + 0.02)(1.10) 22 k = Example 16.1

  26. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers 2000(0.06 + 0.02)(1.10) 22 k = Example 16.1

  27. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units Westerville Auto Parts Number of Containers k = 10 containers k = 8 containers Example 16.1

  28. d = 2000 units/day p = 0.02 day a = 0.10 w = 0.06 day c = 22 units k = 10 containers k = 8 containers Figure 16.4 Westerville Auto Parts Number of Containers

  29. Consistently high quality • Uniform facility loads • Standardized work methods • Close supplier ties • Flexible workforce • Automation • Preventive maintenance • Pull method of materials flow • Line flows Lean Systems in Services

  30. Reduce space requirements • Reduce inventory investment • Reduce lead times • Increase labor productivity • Increase equipment utilization • Reduce paperwork and simple planning systems • Valid priorities for scheduling • Workforce participation • Increase product quality Operational Benefits

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