CHAPTER 12: HIGH VOLUME PRODUCTION SYSTEMS (JIT) LEAN Manufacturing

 

Developed by Japanese in response to their post war situation.

 

RESPONSE TO:

 

1.  Space limitations

 

2.  Desire to improve quality, productivity and costs.

 

3.  Cultural factors

 

4.  Need for importation Desire to export

 

It is a comprehensive Philosophy of Continuous improvement through:

 

1.  People involvement

 

2.  Total Quality Control

 

3.  JIT (Just in time) Production

 

 

    People Involvement

 

A.  Teamwork (Top mgt. to production employees)

 

B.  Discipline--open environment with discipline (std.techniques)

 

C.  Supplier involvement--work with them to solve problems--they are considered to be part of the team

 

 

    Total Quality Control/ASSURANCE:

 

Starts with definition of customers needs by marketing and goes all the way to delivery to customer.  Basic idea:Quality is every employees concern and part of everyone's job.

 

Quality is Fitness for intended use.

 

Everyone looks for ways to do this better.

 

Broad definition of the "customer".  The Next Process is the Customer.

 

How do you control quality?

 

You make sure quality is built into the product, not try to inspect quality into the product.

 

1.  Control "in process"

 

2.  Use automatic inspection devices where possible after each process.

 

3.  Employees responsible for problems--the person(s) responsible correct them but finding the problem source may be group effort. (Quality at the source)

 

4.  Prompt (immediate) feedback is the key.

 

TQC attempts to create a culture of ongoing improvement with "0" defects as the ultimate goal.

 

 

    JIT Production (elements of):

 

Queues are a major waste that JIT fights

 

Queues (up)  WIP (up)  Quality problems (up)   Lead times (up)  Flexibility (down)

 

W.I.P. Covers up problems => remove it and you uncover problems => solve problems => move forward to find and eliminate more.

 

 

A major objective of JIT ==> Have right quantity at the right place at the right time thereby eliminating queues.  Some of the means of achieving this are basic elements of JIT production.

 

1.  A set, uniform production rate

 

2.  Pull method of coordinating work centers [KANBAN]

 

3.  Purchasing and producing in small lots (ideal lot size is 1 => maximizes flexibility)

 

4.  Quick inexpensive setups

 

5.  Multi-skilled workers and flexible facilities

 

6.  High quality levels

 

7.  Effective preventive maintenance

 

8.  Continual work to improve

 

LEAN Production/Service is the Big JIT repackaged. Emphasis is on elimination of waste, no matter where it is found.  It is applicable to any type of business.