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1、BeniAsllaniUniversityofTennesseeatChattanoogaLeanProductionOperationsManagement-5thEditionChapter15RobertaRussell&BernardW.Taylor,IIICopyright2006JohnWiley&Sons,Inc.LectureOutlineBasicElementsofLeanProductionBenefitsofLeanProductionImplementingLeanProductionLeanServices2Cop
2、yright2006JohnWiley&Sons,Inc.LeanProductionDoingmorewithlessinventory,fewerworkers,lessspaceJust-in-time(JIT)smoothingtheflowofmaterialtoarrivejustasitisneeded“JIT”and“LeanProduction”areusedinterchangeablyMudawaste,anythingotherthanthatwhichaddsvaluetotheproductorservice3Cop
3、yright2006JohnWiley&Sons,Inc.WasteinOperations4Copyright2006JohnWiley&Sons,Inc.WasteinOperations(cont.)5Copyright2006JohnWiley&Sons,Inc.WasteinOperations(cont.)6Copyright2006JohnWiley&Sons,Inc.BasicElementsFlexibleresourcesCellularlayoutsPullproductionsystemKanbanproductionc
4、ontrolSmalllotproductionQuicksetupsUniformproductionlevelsTotalproductivemaintenanceSuppliernetworks7Copyright2006JohnWiley&Sons,Inc.FlexibleResourcesMultifunctionalworkersperformmorethanonejobgeneral-purposemachinesperformseveralbasicfunctionsCycletimetimerequiredforthework
5、ertocompleteonepassthroughtheoperationsassignedTakttimepacesproductiontocustomerdemand8Copyright2006JohnWiley&Sons,Inc.StandardOperatingRoutineforaWorker9Copyright2006JohnWiley&Sons,Inc.CellularLayoutsManufacturingcellscomprisedofdissimilarmachinesbroughttogethertomanufactur
6、eafamilyofpartsCycletimeisadjustedtomatchtakttimebychangingworkerpaths10Copyright2006JohnWiley&Sons,Inc.CellswithWorkerRoutes11Copyright2006JohnWiley&Sons,Inc.WorkerRoutesLengthenasVolumeDecreases12Copyright2006JohnWiley&Sons,Inc.PullSystemMaterialispulledthroughthesystemwhe
7、nneededReversaloftraditionalpushsystemwherematerialispushedaccordingtoascheduleForcescooperationPreventoverandunderproductionWhilepushsystemsrelyonapredeterminedschedule,pullsystemsrelyoncustomerrequests13Copyright2006JohnWiley&Sons,Inc.KanbansCardwhichindicatesstandardquant
8、ityofproductionDerivedfromtwo-bininventorysystemMaintaindisciplineofpullpro