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1、Chapter11Just-In-TimeandLeanProductionToAccompanyRussellandTaylor,OperationsManagement,4thEdition,?2003Prentice-Hall,Inc.Allrightsreserved.Producingonlywhatisneeded,whenitisneededAphilosophyAnintegratedmanagementsystemJIT’smandate:EliminateallwasteWhatisJIT?BasicElementsofJI
2、TFlexibleresourcesCellularlayoutsPullproductionsystemKanbanproductioncontrolSmall-lotproductionQuicksetupsUniformproductionlevelsQualityatthesourceTotalproductivemaintenanceSuppliernetworksFlexibleResourcesMultifunctionalworkersGeneralpurposemachinesStudyoperators&improveoper
3、ationsCellularLayoutsGroupdissimilarmachinesinmanufacturingcelltoproducefamilyofpartsWorkflowsinonedirectionthroughcellCycletimeadjustedbychangingworkerpathsThePullSystemMaterialispulledthroughthesystemwhenneededReversaloftraditionalpushsystemwherematerialispushedaccordingtoa
4、scheduleForcescooperationPreventoverandunderproductionKanbanProductionControlSystemKanbancardindicatesstandardquantityofproductionDerivedfromtwo-bininventorysystemKanbanmaintainsdisciplineofpullproductionProductionkanbanauthorizesproductionWithdrawalkanbanauthorizesmovementof
5、goodsTheOriginofKanbana)Two-bininventorysystemb)KanbaninventorysystemReordercardBin1Bin2Q-RKanbanRRQ=orderquantityR=reorderpoint-demandduringleadtimeFigure11.5TypesofKanbansFigure11.6TypesofKanbansKanbanSquareMarkedareadesignedtoholditemsSignalKanbanTriangularkanbanusedtosign
6、alproductionatthepreviousworkstationMaterialKanbanUsedtoordermaterialinadvanceofaprocessSupplierKanbansRotatebetweenthefactoryandsuppliersSmall-LotProductionRequireslessspace&capitalinvestmentMovesprocessesclosertogetherMakesqualityproblemseasiertodetectMakesprocessesmoredepe
7、ndentoneachotherInventoryHidesProblemsLowerLevelsofInventoryExposeProblemsComponentsofLeadTimeProcessingtimeReducenumberofitemsorimproveefficiencyMovetimeReducedistances,simplifymovements,standardizeroutingsWaitingtimeBetterscheduling,sufficientcapacitySetuptimeGenerallythebi
8、ggestbottleneckSMEDPrinciplesSeparateinternalsetupfromexternalsetupC