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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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PRODUCTIONPLANNING AND
CONTROL(MEFB 433)
Dr. Weria Khaksar
Email: [email protected]
Room No. BN-03-08
8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8- JIT & LEANMANUFACTURING
8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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Manufa!u"#n$Lean O%e"a!#n' A e#*+e ,,!e. !/a! u,e,
.#n#.a+ "e,u"e, and %"due, /#$/ 0ua+#!$d, " ,e"1#e,2
ean systems are sometimes re!erred to as Ju,!-#n-!#.e (JIT) systems owin" to their hi"hly #oordinated
a#ti$ities and deli$ery o! "oods that o##ur %ust asthey are needed.
Ju,!-#n-!#.e (JIT)' A /#$/+ "d#na!ed%"e,,#n$ ,,!e. #n /#/ $d, .1e
!/"u$/ !/e ,,!e. and ,e"1#e, a"e%e"f".ed 5u,! a, !/e a"e needed2
ean manu!a#turin" was de$elo&ed 'y the (a&aneseautomo'ile manu!a#turer )oyota.
An!/e" ea.%+e' the *eneral +otors ,*+ /812and N++4 ,New nited +otor +anu!a#turin"5 4n#.
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Manufa!u"#n$T/e T!a A%%"a/'
Muda' Waste and ine7#ien#y. )he dri$in"&hiloso&hy.6an*an' manual system that si"nals theneed !or &arts or materials.
Pu++ 7,!e.' Re&la#in" material or &arts 'asedon demand9 &rodu#e only what is needed.e#5un9a' ariations in &rodu#tion $olume leadto waste.
6a#:en' ;ontinuous im&ro$ement o! thesystem.
J#d9a' <uality at the sour#e. Ea#h worker ise=&e#ted to &er!orm on"oin" >uality assuran#e.
P9a-9e' ?a!e"uards 'uilt into a &ro#ess to
8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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Manufa!u"#n$T/e $a+, and *u#+d#n$ *+9, f +ean
,,!e.,'
Disru&tions ha$ea ne"ati$einuen#e on thesystem 'yu&settin" thesmooth ow o!
&rodu#ts throu"hthe system5 andthey should 'eeliminated.Disru&tions are
#aused 'y &oor>uality5e>ui&ment'reakdowns5#han"es to the
s#hedule5 and
Waste re&resentsun&rodu#ti$e
resour#es andeliminatin" waste#an !ree u&resour#es andenhan#e
&rodu#tion. )here are se$enwastes in the lean&hiloso&hy:/. 4n$entory
1. A$er&rodu#tion3. Waitin" time. nne#essary
trans&ortin"6. Cro#essin"
waste
. 4ne7#ient work
e=i'lesystem is onethat is ro'ustenou"h tohandle a mi= o!
&rodu#ts5 o!tenon a daily 'asis5and to handle#han"es in the
le$el o! out&utwhile stillmaintain'alan#e ands&eed.
8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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Manufa!u"#n$
BUILDING BLOC67' P"du! De,#$n
•
7!anda"d %a"!,' the workers ha$e !ewer&arts to deal with5 and trainin" times and#osts are redu#ed. Cur#hasin"5 handlin"5and #he#kin" are more routine and lendthemsel$es to #ontinual im&ro$ement. )he
&ro#esses #an 'e standardiFed.• Mdu+a" De,#$n' an e=tension o! standard
&arts. +odules are #lusters o! &arts treatedas a sin"le unit.
•;ua+#!' <uality is the sine >ua non o! lean.4t is #ru#ial to lean 'e#ause &oor >uality #an#reate ma%or disru&tions.
• Cnu""en! En$#nee"#n$' En"ineerin"#han"es #an 'e $ery disru&ti$e to smootho&erations. ;on#urrent en"ineerin"
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Manufa!u"#n$
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• 7.a++ L! 7#:e,' 4n lean &hiloso&hy5 theideal lot siFe is one unit5 a >uantity that maynot always 'e realisti#. BeneGts:
• 7e!u% T#.e Redu!#n' ?mall lots and#han"in" &rodu#t mi=es re>uire !re>uentsetu&s.
8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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•
;ua+#! I.%"1e.en!'
• P"du!#n F+e#*#+#!'
8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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8/16/2019 CHAPTER 8-JIT & Lean Manufacturing #
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Manufa!u"#n$
JIT II' 4n some instan#es5 #om&aniesallow suppliers to mana"eresto#kin" o! in$entory o'tained!rom the su&&liers. su&&lier
re&resentati$e works ri"ht in the#om&anyHs &lant5 makin" sure thereis an a&&ro&riate su&&ly on hand.
)he term JIT II is used to re!er tothis &ra#ti#e. (4) 44 was &o&ulariFed'y the Bose ;or&oration. 4t is o!ten
re!erred to as vendor-managed