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Lean=JIT=Kaizen=World Class Manufacturing=Toyota Production System

Lean=JIT=Kaizen=World Class Manufacturing=Toyota Production System. Two Dreams Best Products for Customers Best Worklife for Employees. Sport Obermeyer. JIT Is NOT. Just Prompt Delivery Last Minute Activity Without Much Planning An Inventory System. JIT Redefines Waste.

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Lean=JIT=Kaizen=World Class Manufacturing=Toyota Production System

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  1. Lean=JIT=Kaizen=World Class Manufacturing=Toyota Production System Two Dreams Best Products for Customers Best Worklife for Employees

  2. Sport Obermeyer

  3. JIT Is NOT • Just Prompt Delivery • Last Minute Activity • Without Much Planning • An Inventory System

  4. JIT Redefines Waste Traditional Waste Definition • Focus is on the PROCESS • Optimization of each operation • Idle Men or Machines • Any Under-capacity Operation

  5. JIT Redefines Waste • JIT Waste Definition • Focus is on OUTPUT of the Process • Idle Inventory • Any Activity That Does Not Add Value • Don’t Make or Do Anything Until It Is Needed • Optimize the Entire Flow - Not Just A Process

  6. Seven Wastes • Defects • Overproducing • Idle / Unnecessary Inventory • Waiting • Unnecessary Process Steps • Unnecessary Worker Movement • Unnecessary Materials Movement

  7. Just-in-Time • Fundamental Objectives • Eliminate Waste • Increase Flexibility • Reduce Lead Times • JIT is a Pull Process • Final Customer • Manufacturing Processes • Basic Raw Material

  8. Just-in-Time • Align Supply Chain Strategies • Inventory Levels, Fill Rates • Inventory Locations • Postponement • Collaborative Logistics • Supplier Strategic Focus

  9. JIT Prerequisites • JIT Prerequisites • Stable Design • Stable Schedule • Faultless Shop Floor Quality • Absolutely Reliable Supply Base • Quality • On-Time Delivery • Accurate Data

  10. JIT Features • Pull, Not Push System • Improves Material Flow, Reduces Throughput Time • Minimizes WIP Inventories • Improves Shop Floor Quality • Reduces Protection Inventories • Improves Supplier Quality, On-Time Delivery • Reduces Protection Inventories • Reduced Set-Ups • Increases Flexibility, Reduces Lot Sizes • Reduces WIP Inventories

  11. JIT Features, cont. • Improved Maintenance Assures Machine Availability • Reduces Protection Inventories • Reduced Inventory Storage Need Reduces Space Requirements • Reductions in Inventories From JIT Implementation are By-products of Process Improvements • The Major Benefit of JIT is Improved Quality

  12. JIT Implementation • Kanban - Pull System • Set-up Reduction • Cellular Layout (flow) • Statistical Process Control on the Shop Floor • Preventive Maintenance • Multifunctional Workers • Jidoka

  13. JIT Impacts on Supply and Logistics Management • Purchasing • Few Suppliers, Long Term Close Relationships • Receiving • No Receiving, No QC Checks • Inventory Levels • Minimal Raw Materials • MRO May Be Stable • JIT Logistics Costs • Specialized Equipment • Consolidation, Full Use of Equipment

  14. Vendor Managed Inventory • Suppliers Manage Inventories of Materials They Supply • May, or Man Not Include Consignments • Process • Supplier and Buyer AGREE on Policies • Supplier and Buyer AGREE on Levels and Bounds • Within the Above Bounds, Supplier Orders and Maintains Inventory

  15. Coordinated Supply Chain Design

  16. Key Concepts • Clockspeed • Logistics Design • Modularity • Standardization • Push/Pull Boundaries • Early Supplier Involvement • CPFR

  17. Logistics Design • Distribution Network • Consolidation • Product and Packaging Design • UPS/FedEx Dimensional Weights • Recycling

  18. Standardization • Internal • Processes • Materials • Equipment • External • Industry Standards (Materials) • Industrial Standardization (SAE) • Multi-Industry (ANSI, ASTM) • International (ISO, Metrics)

  19. Standardization • Industry Standards • Company Standardization • Impacts on Inventory • Impacts on Purchasing • Impacts on Maintenance and Repair • Impacts on Quality • Implementation

  20. Standardization in Logistical System Design • Evaluate Material Flow • Pallets • Cartons • International Influences • Design System Characteristics • Standardize Pallets • Pallet Racks • Material Handling Equipment

  21. Euro Pallet Dimensions • A Euro pallet is a block-style pallet that measures 800mm x 1200mm (31 1/2" x 47 1/4"). • Half pallets are 800mm x 600mm. • Quarter pallets are 400mm x 600mm. • Eighth pallets are 400mm x 300.

  22. Euro Pallet Collars • Euro pallet collars are a clever European innovation designed with reusability and practicality in mind. Euro pallet collars are collapsible, wooden frames that affix easily to standard 800 x 1200 mm euro pallets.Pallet collars can also be used to build temporary bins for storing all kinds of products including fruits and other agricultural items. Orchard and garden owners in particular will appreciate our sturdy collars configured as wooden bins for their reusability and minimal storage space needs.

  23. Euro Pallet Collars

  24. Euro Pallet Collars

  25. Recycled Plastic Euro Pallets

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