JIT和精益生产(英)

ToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.Chapter11Just-In-TimeandLeanProductionToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.ToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.Producingonlywhatisneeded,whenitisneededAphilosophyAnintegratedmanagementsystemJIT’smandate:EliminateallwasteWhatisJIT?ToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.BasicElementsofJIT1.Flexibleresources2.Cellularlayouts3.Pullproductionsystem4.Kanbanproductioncontrol5.Small-lotproduction6.Quicksetups7.Uniformproductionlevels8.Qualityatthesource9.Totalproductivemaintenance10.SuppliernetworksToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.FlexibleResourcesMultifunctionalworkersGeneralpurposemachinesStudyoperators&improveoperationsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.CellularLayoutsGroupdissimilarmachinesinmanufacturingcelltoproducefamilyofpartsWorkflowsinonedirectionthroughcellCycletimeadjustedbychangingworkerpathsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.ThePullSystemMaterialispulledthroughthesystemwhenneededReversaloftraditionalpushsystemwherematerialispushedaccordingtoascheduleForcescooperationPreventoverandunderproductionToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.KanbanProductionControlSystemKanbancardindicatesstandardquantityofproductionDerivedfromtwo-bininventorysystemKanbanmaintainsdisciplineofpullproductionProductionkanbanauthorizesproductionWithdrawalkanbanauthorizesmovementofgoodsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.TheOriginofKanbana)Two-bininventorysystemb)KanbaninventorysystemReordercardBin1Bin2Q-RKanbanRRQ=orderquantityR=reorderpoint-demandduringleadtimeFigure11.5ToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.TypesofKanbansFigure11.6ToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.TypesofKanbansKanbanSquareMarkedareadesignedtoholditemsSignalKanbanTriangularkanbanusedtosignalproductionatthepreviousworkstationMaterialKanbanUsedtoordermaterialinadvanceofaprocessSupplierKanbansRotatebetweenthefactoryandsuppliersToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.Small-LotProductionRequireslessspace&capitalinvestmentMovesprocessesclosertogetherMakesqualityproblemseasiertodetectMakesprocessesmoredependentoneachotherToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.InventoryHidesProblemsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.LowerLevelsofInventoryExposeProblemsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.ComponentsofLeadTimeProcessingtimeReducenumberofitemsorimproveefficiencyMovetimeReducedistances,simplifymovements,standardizeroutingsWaitingtimeBetterscheduling,sufficientcapacitySetuptimeGenerallythebiggestbottleneckToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.SMEDPrinciples1.Separateinternalsetupfromexternalsetup2.Convertinternalsetuptoexternalsetup3.Streamlineallaspectsofsetup4.PerformsetupactivitiesinparalleloreliminatethementirelyToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.UniformProductionResultsfromsmoothingproductionrequirementsKanbansystemscanhandle+/-10%demandchangesSmoothsdemandacrossplanninghorizonMixed-modelassemblysteadiescomponentproductionToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.Mixed-ModelSequencingExample11.2ToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.QualityattheSourceJidokaisauthoritytostopproductionlineAndonlightssignalqualityproblemsUndercapacityschedulingallowsforplanning,problemsolving&maintenanceVisualcontrolmakesproblemsvisiblePoka-yokepreventsdefectsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.KaizenContinuousimprovementRequirestotalemploymentinvolvementEssenceofJITiswillingnessofworkerstoSpotqualityproblemsHaltproductionwhennecessaryGenerateideasforimprovementAnalyzeproblemsPerformdifferentfunctionsToAccompanyRussellandTaylor,OperationsManagement,4thEdition,2003Prentice-Hall,Inc.Allrightsreserved.TotalProductiveMaintenance(TPM)BreakdownmaintenanceRepairstomakefailedmachineoperationalPreventivemaintenanceSystemofperiodicinspection&mainten