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Chuah Shu Chin B050810194 Jennise Tan Teng Teng B050810016

8.0 LEAN. Chuah Shu Chin B050810194 Jennise Tan Teng Teng B050810016 Yeow See Leong B050810105. Outline. 8.1 Lean Production and JIT Terms of JIT and Lean Operations Goals of JIT Some impacts in capacity Building blocks 8.2 Pull System. Terms of JIT & Lean Operations.

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Chuah Shu Chin B050810194 Jennise Tan Teng Teng B050810016

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  1. 8.0 LEAN ChuahShu Chin B050810194 Jennise Tan TengTeng B050810016 Yeow See Leong B050810105

  2. Outline 8.1 Lean Production and JIT • Terms of JIT and Lean Operations • Goals of JIT • Some impacts in capacity • Building blocks 8.2 Pull System

  3. Terms of JIT & Lean Operations Just-in-time (JIT):A highly coordinated processing system in which goods move through the system, and services are performed, just as they are needed.

  4. Example

  5. Initially, JIT referred to the movement of materials, parts, and semi-finished goodswithin a production system. • The scope of JIT broadened and became associated with lean operations.

  6. Lean Operations:A highly coordinated system that uses minimal resources and produces high-quality goods or service. • Depends on having high quality processes in place. • The terms JIT/lean operations are often used interchangeably

  7. JIT / Lean Production • A system for scheduling production that results in low levels of work-in-process and inventory. • It encompasses the entire organization. • To pursue a system that functions well with minimal levels of inventories, minimal waste, minimal space, and minimal transactions.

  8. Ultimate Goal A balanced rapid flow Supporting Goals Eliminate disruptions Make the system flexible Eliminate waste Product Design Process Design Personnel Elements Manufacturing Planning Building Blocks Summary JIT Goals and Building Blocks

  9. Goals of JIT Supporting Goals Ultimate Goal is a balanced system. Achieves a smooth, rapid flow of materials through the system. • Eliminate disruptions • Make system flexible • Eliminate waste, especially excess inventory

  10. Sources of Waste • Overproduction • Waiting time • Unnecessary transportation • Processing waste • Inefficient work methods • Product defects

  11. Without JIT • Rack unnecessarily oversized taking up too much space on the line. • Example of wasted non-value-creating space. • Onerous operator task. • Unnecessary motions. • Operator idleness. Example

  12. With JIT • Sequencing on line: e.g.: 2 people-carriers, 1 two-door, 1 saloon car… • Lightened logistics, small trains. • Small containers, less stock. • Line side compression, concentration on added value, reduction of waste. • Flexible multi-product line. • Operators creating added value.

  13. Capacity Capacity: an upper limit on the rate of output.

  14. Some Impacts in Capacity

  15. Building Blocks

  16. 1. Product Design

  17. 2. Process Design

  18. 3. Personnel/Organizational Elements

  19. 4. Manufacturing Planning and Control

  20. PULL SYSTEM

  21. Starts with the last workstation in the production line or with the customer & works backward through the system.

  22. Benefits of Pull System • Better communication • Allow manufacture of only what is needed by the customer • Highlights quality issues quickly • Organize the workplace • Support continuous improvements • Provide a common system for moving material through a plant • Low unit cost • Good customer service

  23. Conclusion of JIT JIT manufacturing is a coordinated production system that enables the right quantities or parts to arrivewhen they are needed precisely where they are needed. Key elements of JIT manufacturing are the pull systemand kanban production, small lot sizes and quick setups, uniform plant loading, flexible resources, and streamlined layout.

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