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Teme de casă liber alese, de preferat realizate la locul de muncă şi bazate pe un studiu
de caz real. Sugestii de teme realizate la liberă alegere :
• Introduction
• Method and Implementation Approach
• Implications for Environmental Performance
• Useful Resources
Introduction
Just-in-time production, or JIT, and cellular manufacturing are closely related, as a cellular
production layout is typically a prerequisite for achieving just-in-time production. JIT leverages
the cellular manufacturing layout to reduce significantly inventory and work-in-process (WIP).
JIT enables a company to produce the products its customers want, when they want them, in the
amount they want.
Under conventional mass production approaches, large quantities of identical products are
produced, and then stored until ordered by a customer. JIT techniques work to level production,
spreading production evenly over time to foster a smooth flow between processes. Varying the
mix of products produced on a single line, sometimes referred to as "shish-kebab production",
provides an effective means for producing the desired production mix in a smooth manner.
JIT frequently relies on the use of physical inventory control cues (or kanban) to signal the need
to move raw materials or produce new components from the previous process. In some cases, a
limited number of reusable containers are used as kanban, assuring that only what is needed gets
produced. Many companies implementing lean production systems are also requiring suppliers to
deliver components using JIT. The company signals its suppliers, using computers or delivery of
empty, reusable containers, to supply more of a particular component when they are needed. The
end result is typically a significant reduction in waste associated with unnecessary inventory,
WIP, and overproduction.
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Key elements of JIT, and techniques for achieving JIT, are discussed below.
Load leveling. This technique involves determining appropriate quantities and types of products
needed in a given day to meet customer orders. This technique allows organizations to produce
products with a variety of customer specifications each day (using a daily schedule), in a smooth
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sequence that minimizes inventory and delay. Takt time is critical to the daily scheduling
required in leveled production described above. It is the rate at which each product must be
completed to meet customer needs, expressed in amount of time per part.
Production Sequencing. This involves calculating the pattern for making each product type in
the required amount for any given day, by calculating the takt time for the daily quantity of each
type.
Kanban. Often referred to as the "nervous system" of lean production, kanban is a key
technique that determines a processes production quantities, and in doing so, facilitates JIT
production and ordering systems. Contrary to more traditional "push" methods of mass
production which are based on an estimated number of expected sales, kanban's "pull" system
creates greater flexibility on the production floor, such that the organization only produces what
is ordered.
More specifically, a kanban1 is a card, labeled container, computer order, or other device used to
signal that more products or parts are needed from the previous process step. The kanban
contain information on the exact product or component specifications that are needed for the
subsequent process step. Kanban are used to control work-in-progress (WIP), production, and
inventory flow.
In this way, kanban serves to ultimately eliminate overproduction, a key form of manufacturing
waste. Different types of kanban include: supplier kanban (indicate orders given to outside parts
suppliers when parts are needed for assembly lines); in-factory kanban (used between processes
in a factory); and production kanban (indicate operating instructions for processes within a
line).
Kanban are a critical part of a JIT system. In implementing a kanban system, organizations
typically focus on four important "rules".
• Kanban works from upstream to downstream in the production process (i.e., starting with
the customer order). At each step, only as many parts are withdrawn as the kanban
instructs, helping ensure that only what is ordered is made. The necessary parts in a given
step always accompanies the kanban to ensure visual control.
• The upstream processes only produce what has been withdrawn. This includes only
producing items in the sequence in which the kanban are received, and only producing
the number indicated on the kanban.
• Only products that are 100 percent defect-free continue on through the production line.
In this way, each step uncovers and then corrects the defects that are found, before any
more can be produced.
• The number of kanban should be decreased over time. Minimizing the total number of
kanban is the best way to uncover areas of needed improvement. By constantly reducing
the total number of kanban, continuous improvement is facilitated by concurrently
reducing the overall level of stock in production.
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Useful Resources
Productivity Press Development Team. Kanban for the Shopfloor (Portland, Oregon:
Productivity Press, 2002).
Footnotes
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6. Utilizarea sistemului Lean Manufacturing pentru îmbunătăţirea fluxului de producţie
dintr-un atelier.
7. Managementul distribuţiei – Strategii de distribuţie.
8. Managementul sistemului de transport şi manipulare
9. Managementul sistemului de depozitare.
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