Sistem Produksi Tepat Pertemuan 1 - TIN416

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SISTEM PRODUKSI TEPAT
WAKTU
(JUST-IN-TIME PRODUCTION
SYSTEMS)
Roesfiansjah Rasjidin
Teknik Industri – Fakultas Teknik
Universitas Esa Unggul
Penilaian Akhir
UAS: 35%
 UTS: 30%
 Tugas/Quiz: 15%
 Kehadiran: 10%
 Partisipasi kelas: 10%

Rencana Perkuliahan
Asal, tujuan & definisi JIT
 Keuntungan,
perbandingan dgn sistem
konvensional, dan skema
JIT
 Konsep 5S dan persiapan
sumberdaya manusia
 Sistem Tarik dan Sistem
Dorong
 Sistem Kanban
 Produksi Lot Kecil
 Reduksi Waktu Set-up






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SMED dan Teknik
Reduksi Waktu Set-up
Pemeliharaan dan
perbaikan mesin dan
peralatan
Teknologi kelompok dan
sel manufaktur
Screening, pokayoke &
jidoka
Leveling production
Sinkronisasi dan
penyeimbangan proses
PENGANTAR

History and Origins of JIT

Definition and Objectives of JIT

JIT Benefits and Success Factors

Comparison: Conventional vs JIT Systems

JIT Scheme
Origins of Just-in-Time




JIT originated in Japan, post WWII
Driven by a need survive after the
devastation caused by the war
JIT gained worldwide prominence in the
1970s
Japanese firms, particularly Toyota, in
1970's and 1980's
© Wiley 2007
Origins of JIT (cont’d)
 Taiichi Ohno and Shigeo Shingo
 Geographical and cultural roots
 Japanese objectives
“catch up with America” (within 3 years of 1945)
small lots of many models
 Japanese motivation
Japanese domestic production in 1949 – 25,622
trucks, 1,008 cars
American to Japanese productivity ratio – 9:1
Era of “slow growth” in 1970's
7
Waste: Time, Material & Resources
Machine downtime
Bad design
Unreliable
supplier
Poor quality
Inefficient layout
Waste Elimination
 Ohno
devised a new system of production based
on the elimination of waste.
 Waste was eliminated by:
 just-in-time - items only move through the
production system as and when they are needed
 autonomation - automating the production
system so as to include inspection - human
attention only being needed when a defect is
automatically detected whereupon the system
will stop and not proceed until the problem has
been solved
JIT Objectives
Ultimate objectives:
 Zero Inventory.
 Zero lead time.
 Zero failures.
 Flow process.
 Flexible manufacture.
 Eliminate waste.
10
JIT Definition
Just-in-time (JIT) is defined in the APICS
dictionary as “a philosophy of
manufacturing based on planned elimination
of all waste and on continuous
improvement of productivity”.
 It also has been described as an approach
with the objective of producing the right
part in the right place at the right time (in
other words, “just in time”).

JIT Benefit Summary
Manufacturing cycle time reduction
Inventory reductions:
Raw materials
Work-in-process
Finished goods
Labor cost reductions:
Direct
Indirect
Space requirements reduction
Quality cost reduction
Material cost reduction
Improvement
Aggregate
percentage
(3-5 years)
80-90%
Annual percentage
30-40%
35-70
70-90
60-90
10-30
30-50
25-60
10-50
20-60
40-80
25-60
5-25
3-20
3-20
25-50
10-30
2-10
12
Just-in-Time
Success Factors
Employee
Empowerment
Suppliers
Quality
JIT
Preventive
Maintenance
Layout
Inventory
Scheduling
Three Elements of JIT
© Wiley 2007
JIT and Competitive Advantage
JIT Requires:
JIT and Competitive Advantage
Which Results In:
Which Yields:
Comparison:
Conventional vs JIT Systems
Conventional
1. Some defect one acceptable
2. Large are efficient (more is better)
3. Fast production is efficient
4. Inventory provides safety
5. Inventory smooths production
6. Inventory is an asset
7. Queues are necessary
8. Suppliers are adversaries
9. Multiple supply sources lead to safety
10. Breakdown maintenance is enough
11. Long lead time is better
12. Setup time is given
13. Management is by edict
14. Work force is specialized
Just - In - Time
1. Zero defect are necessary & attainable
2. Ideal lotsize is one (less is better)
3. Balanced production is efficient
(faster production is a waste)
4. Safety stock is a waste
5. Inventory is undesirable
6. Inventory is a liability
7. Queues should be eliminated
8. Supplier are partners
9. Fewer sources of supply lead to control
10. Preventive maintenance is essential
11. Short lead time is better
12. Setup time should be zero
13. Management is by consencus
14. Work force is multifunctional
Just In Time Scheme
Introduction
of Procedurs
Revolution Awareness
5 S for work place Improvement
Flow Manufacturing
Multi-Process
Handling
Quality Assurance
Leveled Production
Change Over
Maintenance &
Safety
Standard Operation
Jidoka
(Autonomation)
JUST IN TIME
Man Power
Reduction
Visual Control
Kanban
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