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Pull Production Systems 生産システムを引いて- The benefits and a brief description.

Push Production Systems: a forecast of future demand drives production scheduling and material replenishment. Planned orders are used to authorize production or move materials – usually in batch mode
Push Production Systems are…
  • Inherently complex and inflexible
  • Usually computer based (no visible system)
  • Labor intensive, requiring significant labor-hours to keep the system accurate and up-to-date
  • Incapable of reacting quickly or accurately to the frequent, small demand changes common to production operations

A Pull Production System has three major tasks:
  • Get materials to the shop floor based on actual consumption
  • Move work-in-process (WIP) through the shop based on actual customer demand
  • Provide a mechanism for continuously improving the production processes
If the meaning of production control is truly understood, inventory control is unnecessary.                                               -- Taiichi Ohno

Safety Stock is WASTE Safety stock is excess inventory in a system to account for variations in:
  • Demand
  • Lead time
  • Supplier performance
  • Poor quality
  • Differences between calendar days and work days
  • E.g., Production works on Saturday, but suppliers don’t deliver on Saturday

Kanban is a Japanese word, which loosely translated means sign or card We use Kanban signals to pull product through the process, AND to replenish raw material Use Kanban when processes are separated
  • Lines with multiple back ends
  • Outside suppliers
  • Feeder cells
  • Semi-finished goods
  • Finished goods with our customers!

2-Bin Replenishment System Goals of a 2-bin system:
  • Ensure operator always has parts
  • Ensure operator does not have to leave bench to find parts
  • Ensure material availability status is VISIBLE
  • Minimize the amount of raw material kept on the production floor

Kanban and Materials Management
Small parts: use the container/bin as Kanban signal
  • It is the container that goes back and forth for replenishment
Large / expensive parts: use Kanban card Where possible raw material should be removed from stores (warehouse) and put on the production floor in point-of-use (POU) locations.  Strive to eliminate stores.
  • Appropriate quantities in POU depends on:
  • physical size
  • material cost
  • frequency of usage
  • frequency of replenishment

Material Handling Function
In a continuous flow cell, if operators abandon their stations to retrieve parts, the adjacent operations will quickly shut down. A separate material handling role will need to be responsible for part retrieval, removal of empty part containers, and handling of part scrap/fallout

Principles: Consumption is the signal for activity Signal is located in the producing area Producing area is buffered from extreme variation in demand
Benefits: Simplifies planning and control system Converts shop floor into an assembly line Controls production through adherence to pull rules
  • standard containers
  • standard quantities
  • authorized production

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