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Push Vspull - SlideSet9
Push Vspull - SlideSet9
IE 3265 POM
Slide Set 9
R. Lindeke, Sp 2005
Basic Definitions
MRP (Materials Requirements Planning). MRP is the
basic process of translating a production schedule for
an end product (MPS or Master Production
Schedule) to a set of time based requirements for all
of the subassemblies and parts needed to make that
set of finished goods.
Main Advantage of MRP over JIT: MRP takes forecasts for end product
demand into account. In an environment in which substantial variation of sales
are anticipated (and can be forecasted accurately), MRP has a substantial
advantage.
Advantages Disadvantages
JIT PULL
Every job is a High Stress Rush
Limited and known Final Inventory
order
Worker only consume their time &
Balanced systems MUST be in
Raw Materials on what is actually
place
needed
Setup times will greatly impact
Quality MUST be High each piece throughput
has a definite place to go else Any problem will lead to unhappy
immediate feedback is given customers (either internal or
external)
Comparisons (cont.)
Advantages Disadvantages
MRP PUSH
Allows Managers to manage that
Can lead to large inventories
is, plan and control things
Requires intricate knowledge of Can generate large quantities of
Production Times & Product Flow scrap before errors are discovered
Can lead to economies of scale in Requires diligence to maintain
purchasing and production effective product flow
Allows for the planning and
completion of complex assemblies as Requires maintenance of large and
sub-components are delivered only complex databases
by scheduled need
Focusing on JIT
JIT (Just In Time) is an outgrowth of the Kanban system developed by
Toyota.
Kanban refers to the posting board (and the inventory control cards
posted there) where the evolution of the manufacturing process would
be recorded.
The Kanban system is a manual information system that relies on
various types of inventory control cards.
Its development is closely tied to the development of SMED: Single
Minute Exchange of Dies, that allowed model changeovers to take
place in minutes rather than hours.
The Fundamental Idea of JIT and Lean Manufacturing Systems in
General (an Americanization of the Toyota P. S.) is to empower the
workers to make decisions and eliminate waste wherever it is found
The Tenets of JIT/Lean
Eliminate Waste
Waste is anything that takes away from the operations
GOAL (to make a profit and stay in business!)
Reduce inventory to only what is absolutely needed
Improve Quality scrap and rework are costly and disrupt flow
Only make what is ordered
Make setups and changes quickly and efficiently
Employ only the workers needed
Eliminate Clutter it wastes time
Features of JIT Systems
Small Work-in-Process Inventories.
Advantages:
1. Decreases Inventory Costs
2. Improves Efficiency
3. Reveals quality problems (see Figure 7-10)
Disadvantages:
1. May result in increased worker idle time
2. May result in decreased throughput rate
River/Inventory Analogy
Illustrating the Advantages of Just-in-Time
Disadvantages
1. Slow to react to changes in demand
2. Ignores predicted demand patterns (beyond 2 months or so)
Focus on The Kanban
K0: $1000
: $95 for each 7.5% reduction in setup cost
Annual quantity: 48000
Holding cost: $4.50
95 95
MARR is 13% b 1218.55
.07796
ln 1
1 .075
2 .13 1218.55
2 2
K $0.232
48000 4.5
Continuing:
G K 2 K h Ia K
At Min K*:
316.58 1325.47 $1642
EOQ K
2 K 70
h
SMED
Some terms:
CT (min/unit)
Q
Minimum # Workstations reqr:
t
j 1
j
Eff StK
C
t j is the time of any task actually assigned to St K
Lets Try One:
Times:
A 25s; B 33s;C 33s;
A B C D 21s; E 40s; F40s;
G 44s; H 19s
Production
Requirement G H
is 400/shift
D E F
Calculation of Takt Time & Optimal
Station count
N t 25 33 33 21 40 40 44 19
i
4.04
C 63.4
N f 5stations
To Perform Assignment we need
Assignment Rules:
Primary Rule:
Assign task by order of those having largest
number of followers
Secondary Rule:
Assign by longest task time
Primary Assignment Rule
Task # Followers
A,D 4
E,B 3
F,C 2
G 1
Line Balancing Assignments
Feas. Task w/
Remaining Task w/ L.
Station Task T. Time Remaining Most
Time Time
Task followers
A 25 38.4 B, D D B
1
D 21 17.4 -
2 E 40 23.4 -
3 B 33 30.4 -
4 F 40 23.4 -
5 C 33 30.4 -
G 44 19.4 H
6
H 19 .4 -
The Line Balance
A B C
WS 3 WS 5
WS 1 G H
WS 6
D E F
WS 2 WS 4
Checking Efficiencies:
T 255
Eff L 67%
C gN 6 63.4
46
Eff S 1 72.6%
63.4
33
Eff S 3 52.1%
63.4
63
Eff S 6 99%
63.4
Dealing with Efficiencies