Just in Time
Introduction to the Toyota Production System (TPS)
Brief history of Manufacturing 1980’s OPEC oil embargo drives up fuel prices, Japan imports small cars with increased fuel mileage. How we learned about TPS Quality of cars – but not right awayPilgrimages – Hayes, Wheelwright, ClarkJoint ventures – Nummi-Geo…Japanese NA operations-Georgetown, KYJapanese sages- Ohno, Shingo, MondenAmerican translation – “Lean”,…
Read More »Steps to create Value Stream Mapping
A VALUE STREAM MAP IS… A tool that helps visualize and understand the flow of material and information as a product or service makes its way through the value stream: A high-level map that visually presents the flow of a product or service from supplier to customer and can be…
Read More »Types of material replenishment systems
Push System Focuses on maximizing output, optimization of resource utilization (man and machine) A traditional system of production and material planning Relies on Material Requirements Planning (MRP) Production is often in monthly buckets Computer generated schedules Production is usually in batches at every work station Long lead times No visual…
Read More »Jidoka
Quality is built in during every step of the manufacturing process. If equipment malfunctions or defect is detected, machine in question will automatically stops, dragging down the rest of production until the problem is resolved. For the Just-In-Time system, every single part that is made and supplied must meet predetermined…
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5S Audit Checklist and Report
Randomly scheduled audits for compliance are essential to sustain a 5S environment. Frequency of audit dependent on “traffic”, “risk”, demonstrated compliance (sustaining efforts, past audits), etc.
