jueves, 23 de octubre de 2014

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:

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


3 comentarios:

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  2. Alex, excellent content and examples! Keep sharing and adding value to our knowledge.

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