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1、,WorkforceWorkforce integrated,Supply Chains Strategic Flexibility&Just-in-Time(JIT)Class#12,1.Variation kills capacity and adds expense to any processThe faster the flow,the better the process:SpeedCost/InvestmentQualityDependabilityFlexibility,Just-in-Time(JIT)Doctrine:Swift,Even Flows,An integrat
2、ed set of activities designed to.achieve high-volume production using minimal inventoriesraw materialswork in processfinished goodsParts arrive at the next workstation“just in time”,Just-in-Time,JIT:Repetitive production system,usually in small batchesJIT:Characteristic of lean production systems,JI
3、T/Lean Production,Eliminate disruptionsMake system flexible by reduce setup and lead timesEliminate waste,especially excess inventory,JIT Goals,ScrapVendor latenessDesign backlogsWork in processMachine downtime,Engineering design redundanciesInspection backlogsDecision backlogsPaperwork backlogs,Inv
4、entory Hides Problems,Attacks wasteExposes problemsAchieves streamlined production,Inventory Level,Starting,Time+1,Time+2,Time+3,Problems to be solved once exposed,What JIT Does,Waste from overproductionWaste from waiting timeTransportation wasteInventory wasteProcessing wasteWaste of motionWaste fr
5、om product defects,The“Seven Wastes”,Small lot sizesOM basics including process analysisContinuing improvementSet up time reductionSupplier participationVolume and a stable environmentEmployee participation,What JIT Requires,Benefits of Small Lot Sizes,Push system:System for moving work where output
6、 is pushed to the next station as it is completedPull system:System for moving work where a workstation pulls output from the preceding station as needed.(e.g.Kanban),Pull/Push Systems,JIT Logic“Pull”System,Literal translation is signalSignal that the previous process can start producing a part or v
7、endor should send a partCan be paper,electronic,empty box,etc.Inventory level function of the number of Kanban,Kanban,Assembly Line,30 Units,Kanban CardMake 30,30 Units,Kanban CardMake 30,Storage,1 Takes 30,2 Card goesto Inject.Molding,30 Units,4 Card matchedto parts and moved forward,3 Inject.Moldi
8、ngmakes 30,30 Units,Kanban CardMake 30,Kanban Production Control System,Kanban Production Control System,Kanban,SMED=Single Minute Exchange of DiesFast set ups are a requirement for small lot-size,mixed model production,Set up Time Reductions,Set up Time Reductions,Economic batch size is a function
9、of set up timeMany techniques to reduce set ups:pre-set tools,standard fixturesvideo the processoff-line preparation-similar to a formula 1 pit stop,Set up Time Reductions,Supplier delivers smaller quantities when neededA risk is that inventory is simply pushed back to suppliersNeeds integration,com
10、munication,and high levels of quality,JIT Supply,JIT Supply,OperationsLink operationsBalance workstation capacitiesRelayout for flow/cellsEmphasize preventive maintenanceReduce lot sizesReduce set up/changeover times,JIT Implementation,WorkforceLevel payrolls/single job descriptionsUnion cooperation
11、Employee empowerment,JIT Implementation,SchedulesLevel scheduleMixed model productionEstablish freeze windows&“attainment”VendorsReduce lead times/frequent deliveriesQuality expectations,JIT Implementation,Product DesignStandard product configurationStandardize and reduce number of parts Modular des
12、ignProcess design with product design,JIT Implementation,Layout and FlowPlacing work stations close togetherU-shaped linesCell based layouts,JIT Implementation,Departmental Layout,Heat Treat,Cell A,Cell B,Work Cells(“Group Technology”),Cell A,Work Cells(“Group Technology”),Reduced inventory levelsHi
13、gher qualityFlexibility Reduced lead timesIncreased productivity,Benefits of JIT Systems,Increased equipment utilizationReduced scrap and reworkReduced space requirementsPressure for good vendor relationshipsReduced need for indirect labor,Benefits of JIT Systems(contd),My JIT Experience Mini Cases,
14、Caterpillar,Cat D-11Gross Power:34.5 liter V-8(935 hp)Operating Weight:113000 kg(248600 lb)Blade:119”tall by 269 wide,My JIT Experience Mini Cases,United Technologies,Used on everything that flies today from commercial aircraft to the space shuttleAmong the most precise(and expensive)small parts in
15、the world,Numerous Hospitals,My JIT Experience Mini Cases,Emergency rooms“High volume”repetitive surgeryRecovery wards,Management may not be committedWorkers/management may not be cooperativeSuppliers may resist,Obstacles to Conversion,Get top management commitmentDecide which parts need most effort
16、Obtain support of workersStart by trying to reduce setup timesGradually convert operationsConvert suppliers to JITPrepare for obstacles,Converting to a JIT System,The basic goal of the demand flow technology in the service organization is to provide optimum response to the customer with the highest
17、quality service and lowest possible cost.Eliminate disruptionsMake system flexibleReduce setup and lead timesEliminate wasteMinimize WIPSimplify the process,JIT in Service,JIT II:the practice of allowing vendors to manage some aspects of buying their products or services for the buyer,JIT II,Summary JIT Goals and Building Blocks,
