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Taylorism
Advantages to use ten persons Productivity per person Low cost Dexterity Time saved Invention of tools, machines, working procedure Uniformity
Principles of Taylorism Simplification Division of work Division of labour Standardization Sequential process
Advantages
Low cost Standardisation of products and services Birth of brand Birth of multiple units Recognition to the company( against craftsmanship) Specialization Perfection of skills Better customer service in delivery, repairs
Problems?
Planning Inventories Warehouses Internal coordination Integration with suppliers Low variety Low flexibility Delayed reaction to market
7 Wastes of Ohno
- waste from over production, -waste of waiting time , -transportation waste, -processing waste, -inventory waste, -waste of motion, and -waste from product defects
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4 5 6. 7
transportation
Process Stocks, inventories Motion Product defects, parts defects
Right parts reach assembly when these are needed with Flow to approach zero inventory
JIT as a System
As a system, it becomes a collection of techniques and methods for - small batch production, - quality management,( CWTQ) - Total Productive Maintenance ( TPM), and - Production planning
JIT Production
a. Backward Flow Subsequent process withdraws from the preceding process exactly what it needs when it needs it The preceding process produces exactly the same quantity as it is withdrawn We climb further and further up the production flow, ultimately the flow is reversed, not cut off.
place. Source of the information is always the customer and not the plant. Kanban is information and is a signaling system to regulate JIT flows c. Responding individually to individual orders: Customer preferences are becoming more diverse, more personalized and more rigid. Customers differ and base their products on personality. Supplying the same product in same way will only generate useless inventory
c. Pull system: Pull system throughout the plant. Producing what is needed and no more When all queues are driven to zero, inventory is minimized, lead times are shortened Under JIT, ideal lot size is One Typically one tenth of a days production is a lot size Exposes hidden problems of production
d. Zero inventory is non-sense Elimination of inventories means shortages of goods and poor customer service The goal at Toyota is to level the flow. Toyota strives to have needed quantities at needed time
Pre-requisites of JIT
1. A strong, reliable, dedicated, quality and delivery conscious vendor support 2. A highly committed, motivated, flexible, multi-skilled efficient workforce 3. A developed logistics support 4. Decentralized system of authority, transparency and visibility of systems, procedures, performance-orientation through established performance evaluation
1. An advanced communication system 2. Readiness of the organization at all levels to go for change 3. Stable demand 4. Active use of other instruments: Kanban , Andon, Kaizen, Poka Yoke, SMED, TQM(CWQC),TPM.
Limitations of JIT
Cannot respond rapidly to major changes in product, process, technology Not suitable for customized products or engineered products calling for new designs Suitable when materials and components are available in quality and quantity and on time delivery
Small vendors for better coordination and controls Responsible, flexible, committed work force Established work culture Large set up to support small lot sizes
Autonomation
Bring the human touch to the machine so as to prevent the problem Automatic stoppages Boka yoke- fool proofing system
Autonomation
Resulted in concepts of: Have a worker when you need a worker. Multi-skills operators One operator multi-machines Andon Safe operations