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PuMHaMH/20110906
JIT-gameMälardalens högskola
Competetive production systems2012-09-11
Margareta HammarströmPuMHa
AgendaPresentation MH + PuMHaIntroduction JIT – Just In TimeGame 1BreakGame 2Summery
Production developmentManagement and training
ABB
Hydro automation structure
Gargnäs Forsa Trä
Mälarenergi
NCC
MdH
Calesco Foil
Flextronics(Enics)
Margareta Hammarström
Gränges Foral
Stoneridge
Bombardier
Bulten
JIT-game.Just In Time production flow exercise based on push respectively pull approach to show the difference in the resulting flow.
JIT-game A work shop in Just In Time
Just-In-Time
Is an operating methodology having as its basic objective the
systematic elimination of WASTE
Elimination of Waste
Flow EmployeeInvolvement Quality
Uniform plant loadReduced setup timeOverlapping operationPull system (linking operations)JIT purchasing
JIT Philosophy
Wath is Just-In-Time about?It is about elimination the wastes of:TimeOver productionStorageWaitingDelayTransport
It focusses on waste by focussing onTIME
The key themes
Time managementSimplicityVisibilitySynchronisationContinous improvementTotal involvement
Acitvities which cost time and moneyscrap inspection holding receiving accepting requestingenquiring counting transmitting trackingfiling handling picking hiding rework releasing rejectionauthorising servicing issuing recording reviewinglocating fetching placing finding unpacking chasing servicing expediting rectifying measuing repacking copying posting
Each of these adds cost and time to the job:
None of them adds any value
JIT-just In TimeWhat do we need to do - to bring it about?
FlowQualityFlexibilityInvolvement
Patnershipwith supplier
Understand theneed of the customer
IntroductionAnakron Ltd - a company with traditional
manufacturingBREAKStremline Ltd - a company with Just-In-
Time manufacturingSummary and following up of the results
JIT-game A work shop in Just In Time
JIT-Game
Cashflow
Manufacturing
1.To supplier 2.From customer
Leadtime
Material costs
Overhead20%
Materials75%
Direct wage costs5%
Capital Employd
LeadTime
LT
Time
Time
+
-
+
-
JIT-just In TimeWhat do we need to do - to bring it about?
FlowQualityFlexibilityInvolvement
Patnershipwith supplier
Understand theneed of the customer
The three cooks
The productionprocess The customer
The supplier
JIT-just In TimeWhat do we need to do - to bring it about?
FlowQualityFlexibilityInvolvement
Patnershipwith supplier
Understand theneed of the customer
Customer needsTime
Delivery timeLead time
QualityPPM
Cost
JIT-just In TimeWhat do we need to do - to bring it about?
FlowQualityFlexibilityInvolvement
Patnershipwith supplier
Understand theneed of the customer
Flow
Telephone assembly
Telephone assembly
From One person assemblingone productat a time
ToSeveral peopleassemblingseveral products simultaneouslyin a measured flow
Production flowCustomer requirement: 50/day => 400min => 8,0 min/pieceManufacturing time = 45 minNo. of operational steps: 45/8,0 = 5,6 => 6 steps
8,0 8,0 8,0 8,08,0
X XX X
Customer order
Customer
X
5,0
X
Quality
Cp = Tolerance intervall/ 6*sigma
Cpk = (Average value-Tolerance limit)/ 3 sigma
Cp = 1,5Cpk = 1,5
Cp = 1,0Cpk = 1,0
Cp = 0,75Cpk = 0,75
Cp = 1,5Cpk = 0,5
Pareto analysis
02468
1012
Solder
bead
sSho
rt-cir
cuit
Orienta
tion f
ault
Projec
tion
Incor
rect v
alue
TemperatureVia-holePressure
Fixture Fluxing agent Component moulding
Solder beads
Capability studies
Fishbone diagram
Flexibility and involvement
Keywords for all employees: flexibility and involvement.
Minimum requirement: to be able to move up and down the flow by at least one operation.
All employees involved in making continuous improvements.
Remuneration system that encourages flexibility and participation.
To tear down barriers between departments and functions.
Operation1
Operation2
Operation3
Operation4X X X
JIT-just In TimeWhat do we need to do - to bring it about?
FlowQualityFlexibilityInvolvement
Patnershipwith supplier
Understand theneed of the customer
Supplier strategies – Benefits of cooperation
Greater flexibilityGreater certainty in planningLower stock levelsGreater certainty of demandImproved capacity utilisationImproved qualityStreamlined administrationEnhanced competitive position
