生产与运作管理

企业管理,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,Hangzhou,*,Cao Min,*,Nr.,*,生产与运作管理,Production and Operations Management,11 Just in Time and Lean Production System,准时生产和精细生产,11.1 JIT 准时生产的实质,11.2 Kanban System看板控制系统,11.3 Pre-Conditions of JIT组织准时生产的条件,11.4 Lean Product 精细生产,People,Lean Production,Through Waste Elimination,Operational Stability,JIT,Quality,at the,Source,Tools of Lean Manufacturing,Pull Systems/Kanban,A Tool for Implementing Pull Systems,Hangzhou,2023/4/29,1,11.1 JIT,准时生产的实质,Moti,ve:exposes and eliminates waste,and continuing improvement,Need to reduce cost,Traditional Method,(Push),Seller Driven,Modern Method,(Pull),Customer Driven,Selling,Price,Profit =,Cost,+,(SELLER),Selling,Price,-,Cost,=,PROFIT,(MARKET),Hangzhou,2023/4/29,2,Types of Waste,O,verproduction,Waiting,Transportation,I,nventor,y,Inefficient process,ing,Unnecessary motion/movement,Product defects,但凡超出增加产品价值所绝对必要的最少量的设备、材料、零件和工作时间的局部，都是浪费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,Inventory Hides Problemsin Production and Operations Management,Quality,Problems,Material,Shortages,Machine,Breakdowns,Workload,Imbalances,Worker,Absenteeism,Out-of-Spec,Materials,Quality,Problems,WIP Inventory,Problems in Production,water level must be reduced,Hangzhou,2023/4/29,4,JIT philosophy,Just in Time:,producing what the nex,t,downstream workstations need,JIT is a,management philosophy of continuous and forced problem solving.,Supplies and components are pulled through system to arrive where they are needed when they are needed.,deliver the right product,in right quality and right status,in the right quantity,at the right price,in the right place,at the right time,to right people,without any waiting and disjoint from the suppliers to internal process.,Goals:,zero inventory,zero defects,zero setups,zero waste,shorten the response time to customer need,continuing waste elimination,Hangzhou,2023/4/29,5,JIT:stockless production,a ideal standard,a limit with zero,actual production can near to it illimitably,but never touch it.,improvement becomes continuing because of the limit,a method continuing improvement,reduce inventory-expose problems,and bottlenecks,-solve the problems-reduce inventory-,.a process of infinite loop,Hangzhou,2023/4/29,6,11.2 Kanban System,What is kanban?,developed at Toyota 1950s to manage line material flows.,Kanban(Kan=card,Ban=signal),simple movement system,“cards to signal&communicate reorder information,boxes/containers to take“lots of parts from one work station to another.,Server only delivers components to client work station as&when needed(called/pulled).,minimise storage in the production area.,Workstations only produce/deliver components when called(they receive card+empty container).,The work-station produces enough to fill the container,Kanban=an authorization to produce more inventory,We thus limit the amount of inventory in process.,Hangzhou,2023/4/29,7,JIT and Demand-Pull,Customer,Supplier,Supplier,Supplier,Supplier,Final,Assembly,Fabric,Fabric,Fabric,Fabric,Subass,Subass,Call(Kanban)&Pull,Call(Kanban)&Pull,Call(Kanban)&Pull,Push,system:material is,pushed,into downstream workstations regardless of whether resources are available,Pull,system:material is,pulled,to a workstation just as it is needed,Push versus Pull,Toyota,dual-card Kanban system,Production Kanban:,the need to purchase more parts,C,onveyance,Kanban:,the need to withdraw parts from one work center and deliver them to the next work center,Not all companies use the kanban cards for their pull systems.Many companies simply use labels to identify that a container is empty or use areas in their warehouses or production departments to identify a container is empty and needs.,Hangzhou,2023/4/29,9,Function of Kanban,Provides production and/or transportation information.,Prevents overproduction and excessive transportation.,Serves as a work order indicating what has been produced and identifies the physical product,Reveals existing production problems and maintains inventory control,Hangzhou,2023/4/29,10,Process,Final Assembl,y,(F),Procuction Kanban,WS:,A-14,Part Nr.:,NK-200406,Part name:,Brace,Part typ:,KEI-7066,Container,Capacity,Type,Nr.,14,M-1,113412,WS:,A-14,Part Nr.:,NK-200406,Part name:,Brace,Part typ:,KEI-7066,P,receding Process,Lathe Machining,N,ext Process,Component Assembly(E),Conveyance Kanban,Container,Capacity,Type,Nr.,14,M-1,113412,Hangzhou,2023/4/29,11,Diagram of Kanban control,upstream WS,#1,downstream WS,#2,WIP inventory,parts flow,Production kanban and empty container,Production kanban and full container,Conveyance kanban and empty container,Conveyance kanban and full container,Hangzhou,2023/4/29,12,Rules of Kanban,Kanban must be attached to the actual containers of parts,Parts are never to be produced or conveyed without a Kanban,The downstream process draws only what is required by the Kanban from upstrea