1. 2. 3. 4. 5. 6. 7. 8. 9. Flexible resources Cellular layouts Pull production system Kanban production control Small lot production Quick setups Uniform production levels Total productive maintenance Supplier networks
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Cells with Worker Routes
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Worker Routes Lengthen as Volume Decreases
waste, anything other than that which adds value to the product or service
Muda

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Waste in Operations
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Lecture Outline
Basic Elements of Lean Production Benefits of Lean Production Implementing Lean Production Lean Services
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Q = order quantity R = reorder point - demand during lead time
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Types of Kanban
Production kanban

Signal kanban
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Small Lots
Require less space and capital investment Move processes closer together Make quality problems easier to detect Make processes more dependent on each other
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Lean Production
Doing more with less inventory, fewer workers, less spaceBiblioteka Just-in-time (JIT)

smoothing the flow of material to arrive just as it is needed “JIT” and “Lean Production” are used interchangeably
N d L S C
= number of kanbans or containers = average demand over some time period = lead time to replenish an order = safety stock = container size
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Determining Number of Kanbans: Example
d L S C = 150 bottles per hour = 30 minutes = 0.5 hours = 0.10(150 x 0.5) = 7.5 = 25 bottles
Cycle time

Takt time

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Standard Operating Routine for a Worker
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Cellular Layouts

External setup


Separate internal setup from external setup Convert internal setup to external setup Streamline all aspects of setup Perform setup activities in parallel or eliminate them entirely
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Inventory Hides Problems
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Less Inventory Exposes Problems
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Material kanban

Kanban square

Supplier kanban

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Move time

Waiting time

Setup time

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Quick Setups
Internal setup


SMED Principles

Can be performed only when a process is stopped Can be performed in advance
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Sample Kanban
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Origin of Kanban
a) Two-bin inventory system Bin 1 Kanban Bin 2 Reorder card Q-R R R b) Kanban inventory system
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Flexible Resources
Multifunctional workers

perform more than one job general-purpose machines perform several basic functions time required for the worker to complete one pass through the operations assigned paces production to customer demand
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Pull System
Material is pulled through the system when needed Reversal of traditional push system where material is pushed according to a schedule Forces cooperation Prevent over and underproduction While push systems rely on a predetermined schedule, pull systems rely on customer requests
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Determining Number of Kanbans
No. of Kanbans =
average demand during lead time + safety stock container size dL + S N = C where
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Waste in Operations (cont.)
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Waste in Operations (cont.)
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Basic Elements

authorizes production of goods
Withdrawal kanban

authorizes movement of goods
a marked area designated to hold items