Just in time principles Flashcards
Just in time principles
“meet demand instantaneously with perfect quality and zero waste”
(1) Eliminating Waste
- Muda
(2) Total Employee Involvement
(3) Continuous Improvement
- Kaizen
8 types of waste
(1) Overproduction
(2) Waiting time - Machines and people should spend as little time as possible not adding value.
(3) Transport - Avoid moving things around the facility
(4) Process - Is the process necessary
(5) Inventory
(6) Motion - Simplification of actions
(7) Defectives
(8) Human ingenuity
Principles of the TPS vs. Mass Production
Equipment - Highly specialised - General Purpose
Batch size - As large as possible - As close to 1 as pos
Production flow - Push - Pull
Scheduling - Forecast - Level scheduling
Quality policy - Economic Optimization - TQM
Key JIT techniques x5
(1) Kanban
- Pull scheduling
- Level scheduling
(2) Andon
(3) Kaizen
(4) Jidoka
- Resources must go into finding the route cause of production errors (aided by andon)
(5) Pokayoke
- Foolproof error prevention.
Criticisms of JIT
- Early success attributed to unfair competitive practices by Japan and Japanese companies
- Failures in implementation in Western cultures are blamed on culture
- JIT manufacturing is perfectly suited to the motor industry, but not necessarily much more.
5 categories of quality (ref)
Garvin (1984)
- Transscendent
- Manufacturing based
- User based
- Product based
- Value based
Customers expectations are a fundamental determinant of perceived quality
Quality management definition (ref)
Dean & Bowen (1994)
“A philosophy or an approach to management” made up of a “set of mutually reinforcing principles, each of which is supported by a set of practices and techniques”
Statistical Process Control
- Set parameters of interest, which will define the quality of your processes. Then determine your upper and lower bounds
- Sample in order to assass quality on an ongoing proccess
- This will encourage continuous improvement, and will reveal building problems as quickly as possible.
Producer and consumer definitions of quality
Just remember this…
Deming’s 14 points
1) Create constancy of purpose
2) Adopt the new philosophy
3) Cease dependence on mass inspection
4) End practice of awarding business on the basis of price tags
5) Institute modern methods of training
6) Inprove constantly and forever
7) Institute modern methods of supervision
8) Drive out fear
9) Break down organisational barriers
10) Eliminate arbitrary numerical goals
11) Eliminate work standards and quotas
12) REmove barriers that reduce pride of ownership
13) Introduce a vigarous program of education and training
14) Push the 13 points every day
Deming’s quality cycle
Plan –> Do – Check –> Act –> Plan
Principles of TQM
- Customer focus
- Top management leadership
- Statistical reasoning with factual data
- Organisation-wide involvement for continuous improvement
- Teamwork & Participation
- Training & Education
Criticisms of TQM
- Few TQM initiatives resulted in measurable or lasting business results
- TQM is accompanied with “excessive bureaucracy, focus on internal processes, avoidance of genuine organisational reform, faddism,, and lack of innovation within the corporate culture” (Harari, 1997)
3 m’s of waste reduction:
mura - A lack of consistency
muri - absurd or unreasonable
muda - does not ad value to the eoperation or the customer
5 steps to lean (ref)
Jones & Womack
1) Specify value
2) Identify the value stream
3) Make the value flow
4) Pull value
5) Pursue perfection
