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UT Knoxville BUAD 341 - Elements of Lean Production
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BA341 10th Edition Lecture 10Outline of Last Lecture I. HistoryII. The cost of variety III. The lean enterpriseIV. Lean ProductionV. Process FlowVI. Systems for Managing FlowVII. Process Performance MetricsVIII. Little’s Law Outline of Current LectureIX. Emphasize JIT productionX. One-Piece FlowXI. Kanban ProductionXII. Level SchedulingXIII. JIT LayoutXIV.Other Elements of Lean Production Current LectureElements of Lean Production- How much WIP should we have?- High inventory (WIP) hides problems - Lower levels of (WIP) expose problemso If you adopt lean operations then lower inventory gradually- Emphasize JIT productiono Employ a Pull production system How are WIP and Throughput Time in a Pull system compared to a Push System? – Better to adopt the pull system because there is lower inventory and a shorter throughput time. A pull system is demand driven.- Use one-piece flow o Move products one unit at a time, if possible, between workstations to improve throughputThese notes represent a detailed interpretation of the professor’s lecture. GradeBuddy is best used as a supplement to your own notes, not as a substitute.o Requires constant effort to reduce setup timesOne-Piece FlowCase 1 – assume that parts are transferred 60 units at a time. What is the average THt?WIP=3*60=180THr=100 units/hrTHt = WIP / Thr = 180/100 hr = 1.8 h = 1.8 *60 min = 108 minCase 2 – assume that parts are transferred 1 unit at a time. What is the average THt?WIP=3*1=3THr=100 units/hrTHt = WIP / Thr = 3/100 hr = 0.03 h = 0.03 *60 min = 1.8 minElements of Lean Production- Use Kanban Production Control System- Once a kanban (i.e., container) is received, the Machine Center produces a unit to replace the one pulled by the Assembly Line people- The process begins by the Assembly Line people pulling Part A from Storage- Determining the Number of Kanban cards (containers) neededo each container represents the minimum production lot size and o the number of such containers determines directly the amount of WIP in systemo K = (Expected demand during lead time + Safety Stock) / Size of the container = (DL+S)/C D = average demand per period (for assembly line, downstream) L = lead time to replenish an order (upstream) S = safety stock expressed in days (hours, etc.) of demand C = Container sizeA Kanban exampleHobbs Bakery makes cakes that are shipped to grocery stores. The bakery wants to change to a kanban system. Their data is as follows:- Daily demand = 500 cakes- Production lead time = 2 days- Safety stock = 4 hours- Workday length = 8 hours- Container size = 250 cakesHow many Kanban cards do they need? Demand during Lead Time is:- 500 cakes/day * 2 days = 1,000 cakes - Make sure that the time units match!Safety Stock is- 4 hours of demand, i.e., 500 cakes/day * (4hrs/ (8hrs/day)) = 500 cakes/day * 0.5 days = 250 cakes (again, note that units must match!)Then, the number of Kanban containers is- (1,000 + 250)/250 = 1,250/250 = 5Another Kanban ExampleArvin Automotive makes muffler assemblies composed of a muffler and a catalytic converter. The former are made in batches of 10 and the production cell can manufacture a batch in about4 hours. The muffler assembly process averages about eight assemblies per hour. Management carries a safety stock equivalent to 75 minutes of demandHow many Kanban cards are needed to manage this process?The input data is:- Demand = 8 asmbl./hr - Safety Stock = 8 asmbl./hr * (75mins/(60mins/hr)) = 8 asmbl./hr * 1.25hrs = 10 asmbl- Lead time = 4 hrso Demand during Lead Time is 8 asmbl./hr * 4hrs = 32 asmbl- Container size = 10- Then, the number of Kanban containers iso (32 + 10)/10 = 42/10 = 4.2 round up to 5 containersElements of Lean Production- Level Scheduling (Heijunka)o Goal: achieve a smooth, stable production flow. Why would this be desirable?o Idea: process frequent small batches rather than a few large batches  a.k.a. mixed-model (“jelly-bean”) schedule- What does the current layout resemble?- JIT Layout – Group Technology o Group similar products into familieso Group processes in work cellso Use this one for lean production, this layout is job cellsOther Elements of Lean Production- Quality at the source – andon cord- Upgrade housekeeping (5S)o Seiri (Sorting)o Seiton (Simplify)o Seiso (Shine/sweep)o Seiketsu (Standardize)o Shitsuke (Sustain/self-discipline)- Respect for peopleo Crossfunctional teams – sharing info between each department- Preventive maintenanceo Periodic inspection and repair - Standard Worko Use clear, standardized, consistent task specs - Value-chain mappingo Map processes and identify value-added and non-value-added activities - Continuous improvement


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UT Knoxville BUAD 341 - Elements of Lean Production

Type: Lecture Note
Pages: 5
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