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Chapter 8-Process Management: Jit & TQM Issues in Supply Chain Management
Chapter 8-Process Management: Jit & TQM Issues in Supply Chain Management
Chapter 8-Process Management: Jit & TQM Issues in Supply Chain Management
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
2
Chapter Eight Outline
JIT & Supply Chain Mgmt. Workforce Involvement
The Elements of JIT Deming’s Way
Waste Reduction Crosby’s Way
JIT Partnerships
Juran’s Way
JIT Layouts
The Malcolm Baldridge
JIT Inventories
National Quality Award
JIT Scheduling
ISO 9000 Quality Standards
Continuous Improvement
Workforce Commitment The Tools of TQM
JIT II Flow Diagrams
TQM & Supply Chain Mgmt. Check Sheets
The Elements of TQM Pareto Charts
Focus on the customer Cause-&-Effect Diagrams
Statistical Process Control
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
3
Introduction
In 1990s, supply chain management combined:
– Quick response (QR)- speed & flexibility
– Efficient Consumer Response (ECR)- speed & flexibility
– JIT – Continuous reduction of waste
– Keiretsu Relationships- Including suppliers in JIT/TQM efforts
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
4
JIT & Supply Chain Management
JIT emphasizes:
– Reduction of waste
– Continuous improvement
– Synchronization of material flows within the organization
– Channel integration- extending partnerships in the supply chain
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
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JIT & Supply Chain Management- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
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JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Waste Reduction
– Firms reduce costs & add value by eliminating waste from the
productive system.
– Waste encompasses wait times, inventories, material & people
movement, processing steps, variability, any other non-value-
adding activity.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
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JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Just-in-Time Partnerships
– Suppliers & customers work to remove waste, reduce cost, &
improve quality & customer service.
– JIT purchasing includes delivering smaller quantities, at right
time, delivered to the right location, in the right quantities.
– Firms develop JIT partnerships with key customers. Mutual
dependency & benefits occur among JIT partnerships.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
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JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Just-in-Time Layouts
– Move people & materials when & where needed, ASAP.
– Group technology (work cells)- process similar parts or
components saving duplication of equipment & labor
– Work cells are often U-shaped to facilitate easier operator &
material movements.
– JIT layouts are very visual (lines of visibility are unobstructed) with
operators at one processing center able to monitor work at
another.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
9
JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Just-in-Time Inventories
– Reduction of inventory levels causes problems to surface in the
organization.
– Once problems are detected, they can be solved.
– The end result is a smoother running organization with less
inventory investment.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
10
JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Just-in-Time Scheduling
– Small batch scheduling drives down costs by:
• Reducing purchased, WIP, & finished goods inventories
• Makes the firm more flexible to meet customer demand.
– Small production batches are accomplished with the use of
kanbans a Japanese word for card. Although for JIT use, Kanban
has come to mean a signal to order or release material in the
production system.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
11
JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
12
JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Continuous Improvement (Kaizen)
– Continuous approach to reduce process, delivery, & quality
problems, such as machine breakdown problems, setup
problems, & internal quality problems.
– Workforce Commitment
– Managers must support JIT by providing subordinates with the
skill, tools, time, & other necessary resources to identify problems
& implement solutions.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
13
JIT & Supply Chain Management-
Cont.
The Elements of Just-in-Time
– Just-in-Time II
– An extension of supplier partnerships & vendor-managed
inventories.
– A supplier’s employee is housed in the purchasing department of
the buyer’s organization, acting as both buyer & supplier
representative. This employee monitors inventory levels, places
purchase orders, & participates on product design & value
analysis teams.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
14
TQM & Supply Chain Management
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
15
TQM & Supply Chain Management-Cont.
The Elements of Total Quality Management
Deming’s Way
1. Create constancy of purpose to 8. Drive out fear.
improve product & service. 9. Break down barriers between
2. Adopt the new philosophy. departments.
3. Cease dependence on inspection 10.Eliminate slogans &
to improve quality.
exhortations.
4. End the practice of awarding
business on the basis of price. 11.Eliminate quotas.
5. Constantly improve the production 12.Remove barriers to pride of
& service system. workmanship.
6. Institute training on the job. 13.Institute program of self-
7. Institute leadership. improvement
14.Put everyone to work to
accomplish the transformation
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
16
TQM & Supply Chain Management-Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
17
TQM & Supply Chain Management-Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
18
TQM & Supply Chain Management-Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
19
TQM & Supply Chain Management-Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
20
The Tools of TQM
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
22
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
23
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
24
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
25
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
26
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
27
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
28
The Tools of TQM- Cont.
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
29
The Tools of TQM- Cont.
Process Capability
• The current process variation & future changes can be monitored
using a process capability index, or Cpk.
• Cpk is the ratio of the desired process variation to the actual process
variation.
• The process must be under control (only natural variations)
• A Cpk of 1.0- process is capable of producing within the control limits
99.73 percent of the time.
• A Cpk greater than 1.0- even fewer defects.
• Cpk of less than 1.0- process may be incapable of producing within
control limits.
Smallest difference between UCL or LCL and center line
Cpk=
3σ
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
30
The Tools of TQM- Cont.
Acceptance Sampling
• When shipments of product are received from suppliers customers,
samples can be taken & measured against some quality
acceptance standard.
• Sampling is less time-consuming than testing every unit to
determine the overall quality of a shipment.
Producer’s risk-
A buyer rejects a shipment of good quality units because the
sample quality level did not meet standards (type-I error).
Consumer’s risk-
Buyer accepts a shipment of poor-quality units because the sample
falsely provides a positive answer (type-II error).
Principles of Supply Chain Management: A Balanced Approach by Wisner, Leong, and Tan.
© 2005 Thomson Business and Professional Publishing
31