From the JIT Revolution to Lean Manufacturing - Implementing JIT
10 important questions on From the JIT Revolution to Lean Manufacturing - Implementing JIT
An FAS calls for 55 units per hour, resulting from the MPS issuing 11000 units per month. Assuming this company works 20 days a month, how many hours a day is this company producing?
10 hours per day.
11000 units per month/20 days = 550 units per day
550 units per day / 55 units per hour = 10 hours per day
An MPS issues 25600 units per two months. There are 20 working days a month and two 8-hour shifts per day. What is the takt time for this unit?
1,5 minute
25600 units per 2 months / 2 = 12800 units per month
12800 units per month / 20 days per month = 640 units per day
2 x 8-hour shifts per day = 16 hours of production a day
16 hours per day / 640 units per day = 0,025 hours per unit = 1,5 minute per unit
A company decides to change its shifts from four 6-hour shifts a day to three 8-hour shifts a day. The takt time for end-items was 2 minutes in the previous situation. What is the takt time in the new situation?
Exactly the same, since there was no change in amount of working hours or the amount of necessary/demanded end-items.
3x8=24=4x6
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What is a repetitive manufacturing environment?
A (production) system in which discrete parts are produced at a fairly steady flow rate.
In an MRP system unexpected disruptions can be countered by WIP buffers.
How does a JIT system buffer against such disruptions?
By using extra capacity (mainly overtime) as a buffer.
(WIP buffers in a JIT system are very small, most often too small to serve as the only buffer.)
What is the difference between internal and external setups?
External setups are tasks that can be completed while the machine is running.
Internal setups are tasks that require the machine to be stopped.
Obviously keeping a machine running is preferred over stopping it, so external setups are preferred over internal setups.
What are Monden's 4 basic concepts for setup reduction?
1: Seperate internal from external setups
2: Convert as much as possible internal to external setups
3: Eliminate the adjustment process
4: Abolish the setup
- Keeping workers' skills sharp
- Reducing workers' boredom and fatigue
- Fostering appreciation for the overall picture
- Increasing new idea generation
can all be realized by using what?
A worker rotation system.
Name at least 3 things that need to be in place before JIT is effective.
- Production smoothing/heijunka
- Capacity buffers
- Setup reduction
- Cross training and a good plant layout
- Small/less work in progress
In what way does having less WIP influence flexibility? How does quality influence this relation?
Less WIP leads to shorter cycle times and better customer responsiveness. So less WIP leads to higher flexibility. However, when quality is low, production can stop or declines (machine breakdowns, rework etc.). So having low, or less, WIP demands high, or higher, quality.
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