05 05

JUST IN TIME JUST IN TIME

((Sistem Sistem Produksi Produksi Tepat Tepat Waktu Waktu))
Presentasi Kuliah
TKI-313 Sistem Produksi
Jurusan Teknik Universitas Muhammadiyah Surakarta
Dosen : Much Djunaidi
Some Statistics from
1986 ...
A comparison of:
1) assembly hours
2) defects per 100 cars
3) 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 chain
Goods are pulled along
only make and ship what is needed
Smaller lots
Faster setups
Less inventory, storage space
PULL material to next stage
Minimal
or no
inventory
holding
cost
Smaller shipments
Goods are pulled out of
plant 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 Toyoda
President, Toyota
Forms of Waste:
Overproduction
Waiting time
Transportation
Processing Processing
Inventory
Motion
Product Defects
Elimination of Waste
1. Focused factory networks
2. Group technology
3. Quality at the source
4. JIT production 4. JIT production
5. Uniform plant loading
6. Kanban production control system
7. 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 bought
from outside
Axles made and
assembled in house
from outside
supplier
assembled 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 Organizational
Elements
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 always
has 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 into
Workcenter 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! Jika masing jenis kanban tersebut! Jika
perlu, berikan ilustrasinya!
Kumpulkan: 18 Mei 2011, sebelum
kuliah dimulai.