0505JUST IN TIMEJUST IN TIME

((SistemSistem ProduksiProduksi TepatTepat WaktuWaktu))

Presentasi KuliahTKI-313 Sistem Produksi

Jurusan Teknik Universitas Muhammadiyah Surakarta

Dosen : Much Djunaidi

Some Statistics from1986 ...

A comparison of:1) assembly hours2) defects per 100 cars3) average inventory levels

Framingham (GM)

40.7 hours 130 defects 2 weeks

Toyota Takaoka

16 hours 45 defects 2 hours

3) average inventory levels

Post World War II

Growing and rebuilding world economy Demand > Supply US Manufacturing:

Higher volumes Higher volumes Capital substitution Breakthrough improvements The production problem has been solved

View from Japan

Very little capital War-ravaged workforce Little space Poor or no raw materials Poor or no raw materials Lower demand levels Little access to latest technologies

U.S. methods would not work

Japanese Approach to Operations

Maximize use of people Simplify first, add technology second Gradual, but continuous improvement Gradual, but continuous improvement Minimize waste (including poor quality)

Led to the development of the approach known as Just-in-Time

The Toyota Production System

Based on two philosophies:1. Elimination of waste

2. Respect for people

Just-in-Time

Repetitive production system

in which processing and movement of materials and goods occur just as they are

needed

Pre-JIT: Traditional Mass Production

Post-JIT: Lean Production

Tighter coordination along the supply chainGoods are pulled along

only make and ship what is neededSmaller lotsFaster setupsLess inventory, storage spacePULL material to next stage

Minimalor no

inventoryholding

cost

Smaller shipments

Goods are pulled out ofplant by customer demand

JIT Goals(throughout the supply chain)

Eliminate disruptions Make the system flexible Reduce setup times and lead times Minimize inventory Eliminate waste

Waste

Definition:

Waste is anything other than the minimum amount of equipment, materials, parts, space, and workers time, which are absolutely and workers time, which are absolutely essential to add value to the product.

Shoichiro ToyodaPresident, Toyota

Forms of Waste:

Overproduction Waiting time Transportation

Processing Processing Inventory Motion Product Defects

Elimination of Waste

1. Focused factory networks2. Group technology3. Quality at the source4. JIT production4. JIT production5. Uniform plant loading6. Kanban production control system7. Minimized setup times 8. Jidoka and Poka-Yoke

Inventory as a Waste

Requires more storage space Requires tracking and counting Increases movement activity Hides yield, scrap, and rework problems Hides yield, scrap, and rework problems Increases risk of loss from theft, damage,

obsolescence

Examples of Eliminating Wastes

Big Bobs Automotive Axles:

Wheels boughtfrom outside

Axles made andassembled in housefrom outside

supplierassembled in house

BEFORE: Shipping in Wheels

Truck Cost: $500 (from Peoria)

Maximum load of wheels: 10,000

Weekly demand of wheels: 500

AFTER: Shipping in Wheels

Truck Cost: $50 (from Burlington)

Maximum load of wheels: 500

Weekly demand of wheels: 500

What wastes have been reduced?

Process Design

Focused Factories Group Technology Simplified layouts with little storage space Jidoka and Poka-Yoke Minimum setups

Personnel and OrganizationalElements

Workers as assets

Cross-trained workers

Greater responsibility at lower levels Greater responsibility at lower levels

Leaders as facilitators, not order givers

Planning and Control Systems

Small JIT

Stable and level schedules

Mixed Model Scheduling Mixed Model Scheduling

Push versus Pull

Kanban Systems

Kanban

Uses simple visual signals to control production

Examples:empty slot in hamburger chute empty slot in hamburger chute

empty space on floor

kanban card

Kanban Example

Workcenter B uses parts produced by Workcenter A

How can we control the flow of materials so that B alwayshas parts and A doesnt overproduce?

Kanban card: Signal to produce

When a container is opened by Workcenter B, its kanban card is removed and sent back to Workcenter A.This is a signal to Workcenter A to produce another box of parts.

Empty Box: Signal to pull

Empty box sent back. Signal to pull another full box intoWorkcenter B.Question: How many kanban cards here? Why?

Tugas

Cari tahu, apa saja jenis kanban yang biasa diterapkan di lantai produksi?

Jelaskan dengan ringkas, masing-masing jenis kanban tersebut! Jikamasing jenis kanban tersebut! Jikaperlu, berikan ilustrasinya!

Kumpulkan: 18 Mei 2011, sebelumkuliah dimulai.

05JUST IN TIME(Sistem Produksi Tepat Waktu)

Presentasi Kuliah TKI-313 Sistem ProduksiJurusan Teknik Universitas Muhammadiyah Surakarta

Dosen : Much Djunaidi

Some Statistics from1986 ...

Framingham (GM)40.7 hours130 defects2 weeks

Toyota Takaoka16 hours45 defects2 hours

A comparison of:assembly hoursdefects per 100 carsaverage inventory levels

2

Post World War II

Growing and rebuilding world economyDemand > SupplyUS Manufacturing:Higher volumesCapital substitutionBreakthrough improvementsThe production problem has been solved

3

View from Japan

Very little capitalWar-ravaged workforceLittle spacePoor or no raw materialsLower demand levelsLittle access to latest technologies U.S. methods would not work

4

Japanese Approach to Operations

Maximize use of peopleSimplify first, add technology secondGradual, but continuous improvementMinimize waste (including poor quality) Led to the development of the approach known as Just-in-Time

5

The Toyota Production System

Based on two philosophies:1. Elimination of waste

2. Respect for people

6

5

Just-in-Time

Repetitive production systemin which processing and movement of materials and goods occur just as they are needed

7

Pre-JIT: Traditional Mass Production

8

Post-JIT: Lean Production

Tighter coordination along the supply chainGoods are pulled along only make and ship what is needed

9

JIT Goals(throughout the supply chain)

Eliminate disruptionsMake the system flexibleReduce setup times and lead timesMinimize inventoryEliminate waste

10

Waste

Definition:Waste is anything other than the minimum amount of equipment, materials, parts, space, and workers time, which are absolutely essential to add value to the product. Shoichiro Toyoda President, Toyota

11

Forms of Waste:

OverproductionWaiting timeTransportationProcessingInventoryMotionProduct Defects

12

Elimination of Waste

Focused factory networksGroup technologyQuality at the sourceJIT productionUniform plant loadingKanban production control systemMinimized setup times Jidoka and Poka-Yoke

13

6

Inventory as a Waste

Requires more storage spaceRequires tracking and countingIncreases movement activityHides yield, scrap, and rework problemsIncreases risk of loss from theft, damage, obsolescence

14

Examples of Eliminating Wastes

Big Bobs Automotive Axles:

Wheels boughtfrom outsidesupplier

Axles made andassembled in house

15

BEFORE:Shipping in Wheels

Truck Cost: $500 (from Peoria)Maximum load of wheels: 10,000Weekly demand of wheels: 500

16

AFTER: Shipping in Wheels

Truck Cost: $50 (from Burlington)Maximum load of wheels: 500Weekly demand of wheels: 500What wastes have been reduced?

17

Process Design

Focused FactoriesGroup TechnologySimplified layouts with little storage spaceJidoka and Poka-YokeMinimum setups

18

Jidoka is Japanese for Stop everything when something goes wrong, a form of stopping quality problems at their source.Poka-Yoke is Japanese for failproofing: Examples are gasoline nozzles, VCR cassettes (they are ejected if inserted incorrectly), inkjet cartridges, etc.

Personnel and Organizational Elements

Workers as assetsCross-trained workersGreater responsibility at lower levelsLeaders as facilitators, not order givers

19

Planning and Control Systems

Small JITStable and level schedulesMixed Model SchedulingPush versus PullKanban Systems

20

Kanban

Uses simple visual signals to control productionExamples: empty slot in hamburger chute empty space on floor kanban card

21

Kanban Example

Workcenter B uses parts produced by Workcenter A

How can we control the flow of materials so that B alwayshas parts and A doesnt overproduce?

22

When a container is opened by Workcenter B, its kanban card is removed and sent back to Workcenter A.This is a signal to Workcenter A to produce another box of parts.

Kanban card: Signal to produce

23

Empty Box: Signal to pull

Empty box sent back. Signal to pull another full box intoWorkcenter B.Question: How many kanban cards here? Why?

24

Tugas

Cari tahu, apa saja jenis kanban yang biasa diterapkan di lantai produksi?Jelaskan dengan ringkas, masing-masing jenis kanban tersebut! Jika perlu, berikan ilustrasinya!

Kumpulkan: 18 Mei 2011, sebelum kuliah dimulai.

25

The height of the text box and its associated line increase or decrease as you add text. To change the width of the comment, drag the side handle.

X-Axis

Big lot sizesLots of inventoryPUSH material to next stage

Lower per unit cost

Big purchase shipments

Big pushes of finished goods to warehouses or customers

???

The height of the text box and its associated line increase or decrease as you add text. To change the width of the comment, drag the side handle.

X-Axis

Smaller lotsFaster setupsLess inventory, storage spacePULL material to next stage

Minimal or no inventory holding cost

Smaller shipments

Goods are pulled out of plant by customer demand

The height of the text box and its associated line increase or decrease as you add text. To change the width of the comment, drag the side handle.

Warehouse

Bobs

Warehouse

Wheels

The height of the text box and its associated line increase or decrease as you add text. To change the width of the comment, drag the side handle.

Bobs

Wheels

Workcenter A

Workcenter B

Workcenter A

Workcenter B

Kanban Card

Workcenter A

Workcenter B