Just-in-Time and Kanban Chapter 11... Just-in-Time and Kanban • A JIT system means that incoming goods arrive, proceed directly to equipment for processing, become work-in-process, and
Trang 1Donna C. Summers
© 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved
Just-in-Time and Kanban
Chapter 11
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• ‘The next process is the
customer.’
Kaoru Ishikawa
Trang 3Donna C. Summers
© 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved
Just-in-Time and Kanban
• A JIT system means that incoming goods
arrive, proceed directly to equipment for
processing, become work-in-process, and
through value-added activities become
finished goods just-in-time for the
customer to pick up
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• Just-in-time requires three basic
components:
• A Pull system
• Continuous flow processing
• Adherence to Takt times
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© 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved
Just-in-Time and Kanban
• Pull systems
– Pull systems are manufacturing systems that
require that products to be produced only
when needed by a customer
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• Continuous flow processing
– Continuous flow processing focuses on
one-piece-at-a-time production
– Stagnation of work-in-process inventory in
and between processes must be eliminated
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© 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved
Just-in-Time and Kanban
• Takt time
– the rate a process must produce an item in order
to meet customer demand
– Takt time is defined as:
Available working time per day
• Takt time =
-Customer demand rate per day
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• Seven sources of waste were identified by Taiichi
Ohno, also of Toyota Motor Company:
– Waste from overproduction
– waste from inventory
– waste in unnecessary transportation
– waste from producing defects
– waste in processes
– waste in waiting time
– waste in motions.
• Some people have modified this list to include
intellect waste
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© 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved
Just-in-Time and Kanban
• Kanban
– display card in Japanese
– a sign, card, or label, that communicates what
is needed and when
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• Kanban (Pull Inventory Management)
– Kanban improves process management by
focusing on visual control of the process.
– Kanban cards tell the worker what must be
produced as well as what has been produced.
– Workers can not do more than the Kanban
cards tell them to.
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© 2011 Pearson Higher Education, Upper Saddle River, NJ 07458. • All Rights Reserved
Just-in-Time and Kanban
• Jidoka
– the Japanese word for autonomation
– Jidoka is one of the two main pillars of the
Toyota Production system
– When a Jidoka system is present, machines
and equipment are designed to stop
automatically when a problem is detected
Any operator on the line also has the power to stop production
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• Jidoka
– Jidoka systems alert the worker to when a
defective item is produced or a machine
malfunction has occurred
• This allows the problem to be dealt with immediately, preventing the production and passing of defects
• Problems and the defects they cause can be more quickly localized, isolated, and corrected