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Copyright2006JohnWiley Sons Inc BeniAsllaniUniversityofTennesseeatChattanooga LeanProduction OperationsManagement 5thEdition Chapter15 RobertaRussell BernardW Taylor III Copyright2006JohnWiley Sons Inc 15 2 LectureOutline BasicElementsofLeanProductionBenefitsofLeanProductionImplementingLeanProductionLeanServices Copyright2006JohnWiley Sons Inc 15 3 LeanProduction Doingmorewithlessinventory fewerworkers lessspaceJust in time JIT smoothingtheflowofmaterialtoarrivejustasitisneeded JIT and LeanProduction areusedinterchangeablyMudawaste anythingotherthanthatwhichaddsvaluetotheproductorservice Copyright2006JohnWiley Sons Inc 15 4 WasteinOperations Copyright2006JohnWiley Sons Inc 15 5 WasteinOperations cont Copyright2006JohnWiley Sons Inc 15 6 WasteinOperations cont Copyright2006JohnWiley Sons Inc 15 7 BasicElements FlexibleresourcesCellularlayoutsPullproductionsystemKanbanproductioncontrolSmalllotproductionQuicksetupsUniformproductionlevelsTotalproductivemaintenanceSuppliernetworks Copyright2006JohnWiley Sons Inc 15 8 FlexibleResources Multifunctionalworkersperformmorethanonejobgeneral purposemachinesperformseveralbasicfunctionsCycletimetimerequiredfortheworkertocompleteonepassthroughtheoperationsassignedTakttimepacesproductiontocustomerdemand Copyright2006JohnWiley Sons Inc 15 9 StandardOperatingRoutineforaWorker Copyright2006JohnWiley Sons Inc 15 10 CellularLayouts ManufacturingcellscomprisedofdissimilarmachinesbroughttogethertomanufactureafamilyofpartsCycletimeisadjustedtomatchtakttimebychangingworkerpaths Copyright2006JohnWiley Sons Inc 15 11 CellswithWorkerRoutes Copyright2006JohnWiley Sons Inc 15 12 WorkerRoutesLengthenasVolumeDecreases Copyright2006JohnWiley Sons Inc 15 13 PullSystem MaterialispulledthroughthesystemwhenneededReversaloftraditionalpushsystemwherematerialispushedaccordingtoascheduleForcescooperationPreventoverandunderproductionWhilepushsystemsrelyonapredeterminedschedule pullsystemsrelyoncustomerrequests Copyright2006JohnWiley Sons Inc 15 14 Kanbans CardwhichindicatesstandardquantityofproductionDerivedfromtwo bininventorysystemMaintaindisciplineofpullproductionAuthorizeproductionandmovementofgoods Copyright2006JohnWiley Sons Inc 15 15 SampleKanban Copyright2006JohnWiley Sons Inc 15 16 OriginofKanban Copyright2006JohnWiley Sons Inc 15 17 TypesofKanban ProductionkanbanauthorizesproductionofgoodsWithdrawalkanbanauthorizesmovementofgoodsKanbansquareamarkedareadesignatedtoholditems SignalkanbanatriangularkanbanusedtosignalproductionatthepreviousworkstationMaterialkanbanusedtoordermaterialinadvanceofaprocessSupplierkanbanrotatesbetweenthefactoryandsuppliers Copyright2006JohnWiley Sons Inc 15 18 Copyright2006JohnWiley Sons Inc 15 19 Copyright2006JohnWiley Sons Inc 15 20 Copyright2006JohnWiley Sons Inc 15 21 DeterminingNumberofKanbans whereN numberofkanbansorcontainersd averagedemandoversometimeperiodL leadtimetoreplenishanorderS safetystockC containersize Copyright2006JohnWiley Sons Inc 15 22 DeterminingNumberofKanbans Example d 150bottlesperhourL 30minutes 0 5hoursS 0 10 150 x0 5 7 5C 25bottles Roundupto4 toallowsomeslack ordownto3 toforceimprovement Copyright2006JohnWiley Sons Inc 15 23 SmallLots RequirelessspaceandcapitalinvestmentMoveprocessesclosertogetherMakequalityproblemseasiertodetectMakeprocessesmoredependentoneachother Copyright2006JohnWiley Sons Inc 15 24 InventoryHidesProblems Copyright2006JohnWiley Sons Inc 15 25 Copyright2006JohnWiley Sons Inc 15 26 ComponentsofLeadTime ProcessingtimeReducenumberofitemsorimproveefficiencyMovetimeReducedistances simplifymovements standardizeroutingsWaitingtimeBetterscheduling sufficientcapacitySetuptimeGenerallythebiggestbottleneck Copyright2006JohnWiley Sons Inc 15 27 QuickSetups InternalsetupCanbeperformedonlywhenaprocessisstoppedExternalsetupCanbeperformedinadvance SMEDPrinciplesSeparateinternalsetupfromexternalsetupConvertinternalsetuptoexternalsetupStreamlineallaspectsofsetupPerformsetupactivitiesinparalleloreliminatethementirely Copyright2006JohnWiley Sons Inc 15 28 CommonTechniquesforReducingSetupTime Copyright2006JohnWiley Sons Inc 15 29 CommonTechniquesforReducingSetupTime cont Copyright2006JohnWiley Sons Inc 15 30 CommonTechniquesforReducingSetupTime cont Copyright2006JohnWiley Sons Inc 15 31 UniformProductionLevels ResultfromsmoothingproductionrequirementsKanbansystemscanhandle 10 demandchangesSmoothdemandacrossplanninghorizonMixed modelassemblysteadiescomponentproduction Copyright2006JohnWiley Sons Inc 15 32 Mixed ModelSequencing Copyright2006JohnWiley Sons Inc 15 33 QualityattheSource VisualcontrolmakesproblemsvisiblePoka yokespreventdefectsfromoccurringKaizenasystemofcontinuousimprovement changeforthegoodofall JidokaauthoritytostoptheproductionlineAndonscalllightsthatsignalqualityproblemsUnder capacityschedulingleavestimeforplanning problemsolving andmaintenance Copyright2006JohnWiley Sons Inc 15 34 ExamplesofVisualControl Copyright2006JohnWiley Sons Inc 15 35 ExamplesofVisualControl cont Copyright2006JohnWiley Sons Inc 15 36 ExamplesofVisualControl cont Copyright2006JohnWiley Sons Inc 15 37 TotalProductiveMaintenance TPM BreakdownmaintenanceRepairstomakefailedmachineoperationalPreventivemaintenanceSystemofperiodicinspectionandmaintenancetokeepmachinesoperatingTPMcombinespreventivemaintenanceandtotalqualityconcepts Copyright2006JohnWiley Sons Inc 15 38 TPMRequirements DesignproductsthatcanbeeasilyproducedonexistingmachinesDesignmachinesforeasieroperation changeover maintenanceTrainandretrainworkerstooperatemachinesPurchasemachinesthatmaximizeproductivepotentialDesignpreventivemaintenanceplanspanninglifeofmachine Copyright2006JohnWiley Sons Inc 15 39 Unneededequipment tools furniture unneededitemsonwalls bulletins itemsblockingaislesorstackedincorners unneededinventory supplies parts safetyhazardsItemsnotintheircorrectplaces correctplacesnotobvious aisles workstations numberoftimesjobaidsnotavailableorup to date KeeponlywhatyouneedAplaceforeverythingandeverythinginitsplaceCleaning andlookingforwaystokeepcleanandorganizedMaintainingandmonitoringthefirstthreecategoriesStickingtotherules Seiri sort Seiton setinorder Seisou shine Seiketsu standardize Shisuke sustain Copyright2006JohnWiley Sons Inc 15 40 SupplierNetworks Long termsuppliercontractsSynchronizedproductionSuppliercertificationMixedloadsandfrequentdeliveriesPrecisedeliveryschedulesStandardized sequenceddeliveryLocatingincloseproximitytothecustomer Copyright2006JohnWiley Sons Inc 15 41 BenefitsofLeanProduction ReducedinventoryImprovedqualityLowercostsReducedspacerequirementsShorterleadtimeIncreasedproductivity Copyright2006JohnWiley Sons Inc 15 42 BenefitsofLeanProduction cont GreaterflexibilityBetterrelationswithsuppliersSimplifiedschedulingandcontrolactivitiesIncreasedcapacityBetteruseofhumanresourcesMoreproductvariety Copyright2006JohnWiley Sons Inc 15 43 ImplementingLeanProduction UseleanproductiontofinelytuneanoperatingsystemSomewhatdifferentinUSAthanJapa
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