Material Movement in a Lean Manufacturing Operation ??????????

1
Material Movement in a Lean Manufacturing
Operation ??????????

• Total Systems Development
• ???????

2
JIT??(??,????)

• What is meant by the term, Just-In-Time?
• JIT????????
• Does it mean JIT Supply?
• ??,?????
• Does it mean JIT Production?
• ??,?????

3
So, what is Just-In-Time???,??????????

• The concept of producing the necessary units in
  the necessary quantities at the necessary time is
  described by the short-phrase Just-In-Time.
• JIT???????????????????????.

4
For example.

• In building shoes The necessary subassemblies
  of the proceeding process (uppers and bottoms)
  should arrive at the assembly line at the time
  needed in the amounts needed.
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• ?????????????????(?????)???,??,??????????.

5
If we achieve JIT ????????,????

• Unnecessary inventories will be eliminated.
• ??????????
• Stores and warehouses will not be needed.
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• Material carrying costs will be diminished.
• ????????

6
However.

• To rely solely on a central planning approach
  that instructs the production schedules to all
  processes simultaneously is not likely to result
  in a JIT process for all operations.
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7
Typically, one control operation receives the
customers orders and disseminates
schedules.??,????????????,?????????.
Production Control ????
Weekly Schedule??????
8
The problem comes when a change is made either
because the order changes or equipment breaks
down.??????????????????,????????
Production Control ????
Weekly Schedule??????
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The result is excess inventory??????????

• within the plant as Work-In-Process
• ??????????????
• suppliers sending in parts that are not needed
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Additionally??,

• We need extra floor space to store the material.
• ??????????????
• Need expeditors to satisfy the changes in
  schedule.
• ????????????????
• Run overtime to make up parts that we now need.
• ??????????????

11
Toyota rethought how to communicate
schedules.???????????????

• Toyota discovered a different way to manage their
  schedule,
• ??????????????????
• They stopped trying to guess what the customer
  will want.
• ????????????

12
Instead??..

• Each department had installed a small inventory
  of each product.
• ????????????
• Downstream processes come to the supplying
  departments and take what it needs.
• ???????????????????
• This allows the processes upstream to simply
  replace what was taken.
• ??,????????????????.

13
The Toyota Production System
TPS????.

• Is likely to be the most studied and discussed
  operations program in the world.
• ????????????????
• Numerous books and papers have been written about
  TPS.
• ???????TPS????????
• Many have come to characterize TPS as lean
  production or NOS.
• ?????????(TPS)???????????NOS

14
Lean Manufacturing (NOS) NOS????

• Regardless of any authors opinion or rational,
  all agree that the foundation of lean
  manufacturing (NOS) is the continual pursuit to
  eliminate waste.
• ????????????,???????NOS?????????????
• Waste is defined as anything that consumes
  resources or time, but does not add value to the
  product.
• ????????????,???????????

15
Excess Inventory is Waste ??????????

• Excess inventory hides problems
• ????????????

Line Imbalance ?????
Poor Scheduling ????
Quality Problems ????

• Lack of House-
• Keeping
• ??????

Long Set- Up Time ??????
Machine Breakdown ????
????
16
Our goal for materials management in NOS
NOS???????

• The ideal state is a smooth flow of materials
  throughout our own factory
• ???????????????????.
• We want to tie together processes that are
  separated by large physical distances.
• ????????????????????????
• We need to improve communication in regards to
  material movement.
• ???????????????

17
The Push System??????

• In traditional manufacturing, various production
  schedules are released to all processes
  component making and assembly.
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18
The Push System (cont.)??

• These part-making processes produce the parts in
  accordance to their schedules and transport the
  parts to the next process.
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The Push System (cont.)??

• This method makes it difficult to promptly adapt
  to changes.
• ??????????????????
• Each production schedule must be changed at each
  process simultaneously.
• ???????????????????????

20
The Push System (cont.)??

• The Result??
• The company must hold extra inventory among all
  processes.
• ?????????????????
• This creates an imbalance of stock between
  processes.
• ????????????

21
The Pull System ??????

• In contrast, in a PULL SYSTEM, each process
  will withdraw the parts it needs from the
  proceeding process. ??, ??????????????????????
  ????????.

?????
?????
Customer Process ????

• Supplying Process
• ????

22
The Pull System (cont.)????

• Since only the final-assembly process can
  accurately know the necessary timing and quantity
  of parts required, they are the only ones to
  receive a schedule.
• ????????????????????,?????????????.

23
Final Assembly receives a schedule and pulls from
the Market Place. Stitching and Stock-fit
replenishes the Market Place. ????????,????????
???.??????????????.
Production Control ????
Weekly Schedule??????
24
The Pull System (cont.)????

• With the schedule, the final-assembly goes to the
  supplying departments and withdraws what parts
  are needed.
• ??????,??????????????.

25
The Pull System (cont.)????

• The preceding operation then produces the
  replacements of the parts withdrawn by the
  subsequent process. ??,?????????????????????????.

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?????
26
Markets ????

• Markets are the storage locations for all the
  parts prior to going to the next operation.
• ??????????????????????.
• Markets simply are organized collections of
  purchased parts and work-in-process.
• ???????????????????????.
• If parts are already stored in your plant, then
  you can construct markets.
• ??????????,?????????.

27
Cautions about Markets?????????

• Dont get caught up in other peoples philosophy.
• ??????????
• Markets do not have to be located next to the
  receiving docks. ?????????????
• Markets do not have to be large in size.
• ???????
• You can have several mini-markets if space is
  difficult to get. ?????,??????????.
• Use your own common sense
• ????????????!

28
Rules for developing Markets???????

• Have a storage location for every part.
• ??????????
• Determine the maximum of any one part that will
  be stored. ????????????????
• Provide adequate storage space.
• ?????????
• Safety is a priority.
• ?????????.

29
Lessons Learned about Markets??????????

• Have an overflow spot and a means to monitor.
• ???????????
• Try to reserve spaces for future parts.
• ????,????????????
• Preferably, do not store the same part in more
  than one location. ?????????????
• Make sure aisle ways can accommodate forklifts.
• ??????????????.

30
Determine customer demand??????

• Takt time is a reference number that gives you a
  sense for the pace at which each process needs to
  be producing.
• TAKT ?????????????????????????
• To calculate takt time, divide the available time
  by the customer demand.
• ????????????????,
• ??????.

31
For our plant???????

• One shift is nine hours
• there is one 60-minute lunch
• 9??????,???1??????????
• Work-time ????
• 8Hrs. X 60min/hr 480 minutes
• 8?? X 60 480??
• 480 minutes per shift
• There is 28,800 seconds per shift
• 480??????,?28,800?????

32
Customer demand????

• The customer needs 2,000 pairs each day.
• ??????2,000??
• We work one shift each day in Assembly, 6 days
  per week.
• ??????????,????6?
• Customer demand is ??????
• 2,000 Pairs / 28,800 sec
• 2,000? / 28,800?
• or 1 PAIR every 14.4 seconds
• ??14.4???????

33
Market setups and locations???????????

• Locate space within the plant that can be used as
  a market(s).
• ????????????
• Minimize the number of markets.
• If may be necessary to start with several small
  ones, later to combine into one.
• ?????????,??????????????,??????????.

34
Manpower and equipment needed???????

• Parts are delivered to the line by Material
  Handlers using hand-carts.
• ????????????????
• The Material Handler has a designated route that
  covers all the stations he (or she) is
  responsible for.
• ??????????????????????
• He delivers all parts needed on that delivery
  cycle, retrieves all empty containers
• ??????????????,????????

35
Training ??

• ??

• The people who are affected by the new system
  need to understand why the company has
  implemented the program.
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• Those who are to support it must understand how
  it works.
• ???????????????????
• All people must receive adequate training in
  order for the system to be both robust and
  successful.
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36
Training (continued) ??

• Remember who the audience is
• Production workers have little regard for how
  many turns the inventory makes
• Material handlers will not see inventory
  reduction as a benefit.
• ????????
• ????????????????
• ??????????????????

37
Training (continued) ??

• Design your training program(s) using the
  knowledge you
• will gain in the systems development.
• ??????NOS????????????????,
• Keep it simple.
• ?????????,
• Give yourself enough time to handle the tough
  questions.
• Respect the peoples concerns.
• ????????????????,????????

38
Results of a Pull System?????????

• In operations where the implementation has been
  successful, both the management and workforce
  believe the work environment to be enhanced
• ??????????????,??????????????????????????

39
Results of a Pull System?????????

• Where there has been little effort to make the
  system work, the plant typically has shortages
  and misses delivery windows.
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