JIT 1

1
Just In Time (JIT)

• ????

2
Outline

• ??????
• JIT??
• JIT??
• ??
• ??
• ??
• JIT?????
• JIT???

3
??????????
?? PP???? MPS????? RCCP???????? MRP?????? CRP
??????
PP
RCCP
MPS
MRP
CRP
JIT Control
?? Kanban Control???? DBFDrum-buffer-rope
Control Input/Output Control??/???
4
??????

• ??????
• ??
• ??
• ???????
• ????
• ??????
• ?? ?Lead time, cycle time???

5
???????

• ?????(flow manufacturing)
• ?????????????????????????????
• ?????(line balancing)
• ???????????????????????????????,????????
• ?????(level scheduling)
• ????????????????????
• ????(lineraity)
• ?????????????????

6
JIT??

• ?????????????
• ??????????
• ?????????????????
• ????
• ?????
• ???????

7
JIT??
JIT ??
JIT ??
PP
RCCP
MPS
MRP
CRP
JIT ??
8
JIT??

• ????/????
• ????/?????
• ??????
• ?????
• ??
• ????
• ????????
• ?????????
• ??????

9
????

• ?????????????????????????????
• ??
• ??????????
• ?????????.
• ?????????????????, ???????, ????.
• ??

10
?????(Toyota)

• ???????(??????????).
• ?????(???)
• ?????(????????,????????)
• ?????(??????)
• ?????(????????)
• ????????(??????)
• ???????(???????)

11
JIT-?????(one less at a time)

• ?????????(Business Process Reengineering,
  BPR)???,??????,??????,???????.
• ??????????????,?????????????????.

12
???????????????????
??
??
13
??
????
???? ???
???? ???? ???? ??? ???? ??
??
??? ??? ??
????
????
???? ??
????? ????? ?????
?????
?? ??
???? ???? ????
????
??
??
14
??????
15
????-????(Involvement)???(Empowerment)

• ????, ????, ?????????????.
• ?????????????, ???, ?????????.
• ?????????????????????.
• ???????????????????, ?????????.

16
JIT??

• ???????????????????????.
• ??????(TQM,Total Quality Management)?????????,???
  ???????????????????????Kaizan?????PDCA??
• ??(Planning)
• ??(Doing)
• ??(Checking)
• ??(Action)

17
JIT??(?)

• ??????(TPM,Total Preventive Maintenance)?????????
  ?????,?????,??????,??????????????????(Total
  Production Maintenance)????
• ????(TEI,Total Employee Involvement)?????????????
  ?
• ????????????????????.

18
JIT??

• ????(Pull system)????????,??????????
• ???????????????????,??????,??????????????,??????,
  ??????????????.??????.?????????????.

19
JIT??(?)

• ????????(Kanban)???????????????????,?????????????
  ??.
• ??????????????????????????????.

20
(No Transcript)
21
JIT????-?????
???? JIT????
22
?????????????
PUSH ?? ?? ?? ?? ????
?? ?? ?? MPS/FAS
?? ?? ??
?? ??
?? PULL ?? ??
?? ?????? ?? ?? ??
23
MRP JIT
??
JIT
?
?
MRP
???
24
????????

• ??????
• ???????
• ??(??)

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??Kanban??

• ?????????,????????.
• ?????(First In First Out, FIFO)????????????
• ????????????.
• ???????????.?????
• ??(???)????(???)??????,???????.
• ??????????????????????????
• ????????????????????????????

26
????
????
??
27
????

• ?????
• ?????
• ????
• ????
• ?????????
• ?????
• ????

28
?????
?????
?????W/C
? Work Center (W/C)
A
X
B
Y
C
Part
Made in C
29
?????
A-03
A-02
A-01
?wc
?wc
move
P001
F002
use
move
P001 box A-01 box A-02 box F002 box
A-03 box
30
????
Production Kanban
Work center no. P001 Part to be
produced33311-3501 Container capacity 30
units Outbound stock point A-01 Materials
required Material33311-3504
Inbound StockA-05
Material33825-2474 Inbound StockB-03
31
????
Conveyance Kanban
Following W.C.F002 Inbound Stock
Pt.A-02 Outbound Stock Pt.A-01 Preceding
W.C.P001
Part No 33311-3501 Container capacity 30 No. of
kanban released 7 of 12
32
????Refill Kanban
A
A
A
A
B
B
B
B
op1
op2
op3
op4
C
C
C
C
D
D
D
D
E
E
E
E
E
E
E
E
F
F
F
F
F
F
F
F
G
G
G
G
G
G
G
G
H
H
H
H
H
H
H
H
16464
33
?????????Rolling Kanban
Make-to-Stock
x x
A
A
B
B
op4
op3
op2
op1
x x
x
x
C
C
D
D
E E
F
F
Make-to-Stock
G
G
H
H
1632223
34
????
Make-to-Order
Customer orders
x x
op4
op3
op2
op1
x x
x
x
Make-to-Order
3227
35
?????Rework Kanban

• ??????
• ???????????????????????????.
• ?????,?????,??????????????.
• ??????
• ???????????,???????.?????????,???????????????.
• ????????????????????????.

36
????

• ????????????????,??????????,????????????.
• ???????????,?????.
• ????????????????,???????????.

37
????(Theory of Constraint)

• ?????????????????,??????(Constraint)?
• ???,??????
• ???
• ???????????????DBR???(Drum-buffer-rope)???????

38
DBR??

• ???????????(constraint)?????(throughput)???.
• ?(Drum)?????????????
• ??(Buffer)??????,???????????,????
• ?(Rope)???????????????????(gateway operation)
  ,????????,??????????,?????

39
DBR ??
Gateway Operation
constraint
rope
(pull)
drum
buffer
up-stream operations
down- stream operations
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JIT?????
????
???
????
??
Push
?? 1
Pull
Push
?? 2
Pull
Pull
Push
?? 3
Pull
Pull
Pull
41
????
??? ???
forecast
customers
MPS
MRP
wo
po
purchase
suppliers
42
JUST-IN-TIME ?? 1
??? ???
forecast
customers
MPS
MRP
wo
po
purchase
suppliers
43
JUST-IN-TIME ?? 2
??? ???
customers
MPS
MRP
po
purchase
suppliers
44
JUST-IN-TIME ?? 3
??? ???
customers
MPS
MRP
reference
purchase
suppliers
45
???????
????
(????????) ??????
????
??????????????????????????? ????(allowance)?????
??? ?????????
46
???????
???(????)???????. ????????????,???????. ??????????
???????????. ?????????????????????????. ????????
?????????
47
???????
Production Rate 100 pcs/day
customers
Pieces per containerLot size Pcs per
transportationLot size
FG
replen.safety lot no. of time time
size kanban
item
1 0 1 1 0.5 10
4 1 50
101
CP
FG
16
CP
ML
ML
11
suppliers
No. of kanban (r_time s_time)p_ratels/cont
ainer size
48
???ROP???
ROP
OP
SS
????,??????,??????,?????
Kanban
OP
SS
49
JIT???

• ??????
• ??????(shop floor)
• ???????
• ????
• ????
• ?????
• ?????

50
??????

• ????????,???????,???????.
• ???????????,?????????.
• ??????????,???????.

51
?????????

• ??????
• ???????????(??)
• ??????(?????)
• ??????(ECRS?)
• ?????????(????)??
• ????????????????
• ???????????

52
?????
s t e p
Activities
Description of Activity
dis- tance
cum. time
time
op
insp
trans
store
Clean table
1
5
5
2
Prep mold
3
8
Move mold
8m
2
10
3
Asm mold
10
20
4
Aligning
5
25
5
6
Prep tool
2
27
Insp tool
7
5
32
53
ECRS???

• ??(Elimination)?????????
• ??(Combination)????????????
• ??(Rearrange)???????????????
• ??(Simplification)??????????,????????

54
????????(SMED) Single-Minute Exchange of Dies
4.Reduce setup time.
1.Analyze setup.
3.Convert internal to external
2.Separate internal external
55
??????(shop floor)

• ????
• ??????,?????,???/????,????,????????,???
• ???
• ????
• ????
• ???
• ???

56
JIT??????

• ????????,??,??.
• ??????MPS,??????
• ???????BOM
• MRP??????,MRP?????????(Lot for lotLFL)
• ????????????MPS??
• ???MPS???????????????????????????.

57
???????BOM
Modular BOM
Manufacturing BOM
M1
FG
M2
M1
FG
M1
M2
M1
M1
58
JIT????????

• ???????????????(Point of use POU).
• ????,??????(overflow stockroom)????(???)??????.
• ?????????????,??????????.
• ?????????????(cell)????,??????????????????(????).

59
???????

• ???Primary Stockroom??????????????,??????.
• ???Overflow stockroom????????????????????????????
  ?.
• ????????????????????????????????.
• ???????????.

60
???????????
Replenish time0.1 Allowance time0 Lot
size10 No of kanban 100(0.10)10/102 Two
kanbans are re-circulated between overflow
storage and point-of-use storage.
W/C1
W/C2
POU
POU
overflow storage
61
JIT??????

• ???????????????,????????????
• ????????????????,??????????????????????,??????????
  ??????????????????
• ???????????????,?????????????????????????,????????
  ???????
• ????????????????????????????,???????

62
JIT??????

• ???????????????????????????????????????????????
• ???????????????????????????
• ???????????????,???????????????????,??????,???????
  ????
• ???????????????????????

63
?????

• ??????????,????????????
• ???????,?????????????????????????????
• ????????????,??????(EDI)??????????????????????????
  ???????
• ????????????????????????????

64
JIT??????

• ??????????????????,???????????????
• ?????????????????,??????????????????????
• ???????????????????????????????
• ??????????,????????????,????????,????????????

65
???????

• ???????????????????
• ?????????????????????????
• ????????????????????
• ????????
• ??????,????,??????????
• ?????????????????????????????

66
JIT??????

• ????????????????????
• ???????????
• ??????????????????????
• ??????????????????
• ?????????????????????????

67
????????

• ?????????????????,????????????????????????
• ???????,????????????????????????????,??????
• ??????????????????????

68
JIT??????

• ????????????,???????,????????????,?????????????
• ??????????????,?????????????????????
• ?????????????????????????????
• ????????????????????????????????????????,?????????
  ?,????????????????

69
?????
Customer
Customer
Suppliers
Suppliers
70
????
Customized Hub
Customer
Carrier with a fixed schedule
Supplier 1 Supplier 2 Supplier3
71
???????

• ???????????????????????
• ???????????????,????????????,?????????????????????
  ?
• ??????????????????,???????????????????????????????
  ??
• ??????????,???????????????????????,???????????????
  ??,????????

72
JIT?????

• ?????????????????,??????????????,?????
• ??????????JIT,?????JIT?????????
• ?????????????,???????????????????????,????????

73
??

• KANBAN????????.
• ????????TOYOTA????????????,????????????????.
• ???,???????,??????.
• ??????KANBAN?,?????!