Production and Operation Managements Just-in-time Dr.Na GENG Prof.Zhibin JIANG Department of Industrial Engineering Management Shanghai Jiao Tong University
Production and Operation Managements Dr. Na GENG Prof. Zhibin JIANG Department of Industrial Engineering & Management Shanghai Jiao Tong University Just-in-time
国 Just-in-time Contents ●Introduction ·Just-in-time(JT) ·Kanban Introduction
Just-in-time Contents • Introduction • Just-in-time (JIT) • Kanban Introduction
Kanban Introduction Material/Parts Final Finished Customer Supplier assembly goods order Work cell Kanban Kanban Kanban 上浒充通大姿
Kanban Kanban Final assembly Work cell Kanban Material/Parts Supplier Finished goods Customer order Kanban Introduction
Kanban Introduction Kanban(Kan=card,Ban=signal)developed at Toyota 1950s to manage material flow Kanban is an information network used to control production quantities; a communication process that controls the movement of material; a tool to implement JIT Simple movement system √“cards”to signal&communicate reorder information boxes/containers to take "lots"of parts from one work station to another (client-server) 5滑久通人睾
• Kanban ( Kan=card, Ban=signal) developed at Toyota 1950s to manage material flow ; • Kanban is an information network used to control production quantities; a communication process that controls the movement of material; a tool to implement JIT. Simple movement system “cards” to signal & communicate reorder information boxes/containers to take “lots” of parts from one work station to another (client-server). Kanban Introduction
Rules of kanban 1.Parts are never to be produced or conveyed without a Kanban; 2.Kanban comes from downstream process; 3.The upstream process produces items in the quantity and the sequence indicated by the Kanban: 4.The downstream process draws only what is required by the Kanban from upstream processes; 5.Kanban must be attached to the actual containers of parts; 6.Never send defective products to downstream processes. 上浒充通大粤
1. Parts are never to be produced or conveyed without a Kanban; 2. Kanban comes from downstream process; 3. The upstream process produces items in the quantity and the sequence indicated by the Kanban; 4. The downstream process draws only what is required by the Kanban from upstream processes; 5. Kanban must be attached to the actual containers of parts; 6. Never send defective products to downstream processes. Rules of Kanban
Function of kanban Communicates production and transportation information. Communicates production information.It tells what to produce and how many are required.Kanban must be produced in the order received. Provides pick-up and/or transportation information,which includes“where from”and“where to'locations.It can also, in some cases,indicate schedule times for pick-up. Prevents overproduction and excessive transportation by restricting in-bound raw material
• Communicates production and transportation information. • Communicates production information. It tells what to produce and how many are required. Kanban must be produced in the order received. • Provides pick-up and/or transportation information, which includes “where from” and “where to” locations. It can also, in some cases, indicate schedule times for pick-up. • Prevents overproduction and excessive transportation by restricting in-bound raw material. Function of Kanban
Function of Kanban A tool for visual management Allows ordering of multiple lot quantities only to the extent of Kanban available to be replenished. Maintain the production quantity of a process to specific pre- determined lot quantity indicated on the Kanban. Serves as a work order indicating what has been produced and identifies the physical product. ·Improvement tool Reveals existing production problems by reducing the number of Kanban. Helps to reduce passage of defects from one area to another by identifying preceding processes
• A tool for visual management • Allows ordering of multiple lot quantities only to the extent of Kanban available to be replenished. • Maintain the production quantity of a process to specific predetermined lot quantity indicated on the Kanban. • Serves as a work order indicating what has been produced and identifies the physical product. • Improvement tool Reveals existing production problems by reducing the number of Kanban. Helps to reduce passage of defects from one area to another by identifying preceding processes. Function of Kanban
Preconditions of Kanban Standardization of Synchronized processes production Four pre-conditions for the successful implementation of Kanban Quick Changeover Leveling production procedures 上泽充鱼大粤
Standardization of processes Synchronized production Leveling production Quick Changeover procedures Preconditions of Kanban Four pre-conditions for the successful implementation of Kanban
Preconditions of Kanban Leveling production: .Multi-product mix production; .Smooth and balanced production; Balanced not only in yield,but also in product mix,time and load. .In order to reduce inventory level of final products. Example:25 days in May and 7h of working time every day. Product Demand Output/day Takt Time (min) A 400 16 26.2 B 300 12 35 C 200 8 52.5 D 100 4 105 Sum 1000 40 10.5 上泽充道大姿
Preconditions of Kanban Example：25 days in May and 7h of working time every day. Leveling production: •Multi-product mix production; •Smooth and balanced production; •Balanced not only in yield, but also in product mix, time and load. •In order to reduce inventory level of final products. Product Demand Output/day Takt Time (min) A 400 16 26.2 B 300 12 35 C 200 8 52.5 D 100 4 105 Sum 1000 40 10.5
Preconditions of Kanban Product Demand Output/day Takt Time (min) A 400 16 26.2 B 300 12 35 C 200 6 52.5 D 100 4 105 Sum 1000 40 10.5 Mix 1:A:400-B:300-C:200-D:100,cycle only once per month; Mix 2:A:100-B:75-C:50-D:25,cycle 4 times per month; Mix 3:A:4-B:3-C:2-D:1,cycle 100 times per month; Mix 4:ABCABCABAD,A cycle 400 time per month,B 300 time per month,C 200 times per month,and D 100 times per month. 上泽充道大姿
Preconditions of Kanban • Mix 1: A: 400-B:300-C:200-D:100, cycle only once per month; • Mix 2: A:100-B:75-C:50-D:25, cycle 4 times per month; • Mix 3: A:4-B:3-C:2-D:1, cycle 100 times per month; • Mix 4: ABCABCABAD, A cycle 400 time per month, B 300 time per month, C 200 times per month, and D 100 times per month. Product Demand Output/day Takt Time (min) A 400 16 26.2 B 300 12 35 C 200 8 52.5 D 100 4 105 Sum 1000 40 10.5