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2. . . The TPS Approach to Productivity. Elimination of waste Efforts concentrated on shop floorRespect for peopleQuality improvement focusKey elements of our planning approach are changed!!!!. 3. . . Minimizing Waste: Uniform Plant Loading. Not uniformJan. UnitsFeb. UnitsMar. UnitsTotal1,2003,5004,3009,000.
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1. 1 Planning with JIT ISQA 459 Mellie Pullman
2. 2 The TPS Approach to Productivity Elimination of waste
Efforts concentrated on shop floor
Respect for people
Quality improvement focus
Key elements of our planning approach are changed!!!!
3. 3 Minimizing Waste: Uniform Plant Loading
4. 4 Mixed Batch Example Company produces three products with a mixed model assembly line.
Operates 16 hours per day for 250 days/yr.
Determine the mixed model MPS for a daily batch.
Determine minimum batch MPS and the mix schedule for a day.
5. 5 Calculations
6. 6 Mixed Batch Example Company produces four products with a mixed model assembly line.
Operates 8hours per day for 250 days/yr.
Determine the mixed model MPS for a daily and hourly batch .
Determine mix schedule for a day.
7. 7 How to order parts: Kanban Production Control Systems
8. 8 Determining the Number of Kanbans Needed Setting up a kanban system requires determining the number of kanbans (or containers) needed.
Each container represents the minimum production lot size.
An accurate estimate of the lead time required to produce a container is key to determining how many kanbans are required.
9. 9 The Number of Kanban Card Sets
10. 10 Example of Kanban Card Determination: Problem Data A switch assembly is assembled in batches of 4 units from an upstream assembly area and delivered in a special container to a downstream control-panel assembly operation.
The control-panel assembly area requires 5 switch assemblies per hour.
The switch assembly area can produce a container of switch assemblies in 2 hours.
Safety stock has been set at 10% of needed inventory.
11. 11 Example of Kanban Card Determination: Calculations
12. 12 JIT Requirements: Process Changes that affect planning Link operations
Balance workstation capacities
Re-layout for flow
Emphasize preventive maintenance
Reduce lot sizes
Reduce setup/changeover time
13. 13 JIT Requirements: Improve Product Design Standard product configuration
Standardize and reduce number of parts
Process design with product design
Quality expectations
14. 14 JIT Requirements: Work with Vendors Reduce lead times
Frequent deliveries
Project usage requirements
Quality expectations
15. 15 MRP and JIT
16. 16 MRP Small Bucket Approach
17. 17 MRP Balanced Flow
18. 18 MRP vs. The Supermarket