单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,Unit 4 JIT and Lean Production,Contents,Development of Materials Management System,Push System,Pull System,Just-in-time Logistics,The Agile Supply Chain Competing in Volatile Markets,Development of Materials Management System,Push System,Pull System,Period Batch Control,Materials Requirements,Planning(MRP),Push System,Material is pushed from the production facility through distribution until the product reaches the customer based on forecast or schedules.,Benefits,Liabilities,Smaller manufacturing plant warehouses,Increased safety stock and inventory carrying costs,Enhanced customer satisfaction,Increased distribution requirements,Lower transportation costs,Reduced supply chain flexibility,Table 4-1 Features of a Push Distribution System,Pull System,In a Pull system,an order from a customer generates an order from the DC,which triggers production run to replenish the plant warehouse.,Figure 4-1 A Typical Pull Distribution System,Pull System,Benefits,Reduced safety stock and system-wide inventory levels,No stock transfers between DCs are required to cover regional demand variability,Direct shipments from the manufacturing plant to the customer,Liabilities,Larger on-site manufacturing warehouses,Reduced customer satisfaction from slower order fill time,Higher transportation costs as shipments from manufacturing are less full and more frequent,Pull System,Figure 4-2 The Counter-flow of Pull and Push System,Pull System,Figure 4-3 A Comparison of Push and Pull Systems,Pull System,A hybrid approach of both systems requires storing slower-moving items in a smaller warehouse at the plant while pushing truckload quantities of more popular items to the DCs.,Figure 4-4 A Hybrid of Push and Pull Distribution System,Just-in-time Logistics,Just-in-time Origin,JIT is a manufacturing/delivery process where a minimum of goods are kept in stock and items are planned to arrive precisely at the time they are required for use or dispatch.,Henry Ford described essentially the same process,although it wasnt then named,in his autobiography My Life and Work in 1922.,Toyota named the process in the 1950s and it spread to the US and UK in the 1970s.,Just-in-time Logistics,Waste and Variability Reduction,Waste is anything that does not add value from the customer point of view.,Faster delivery,reduced work-in-process,and faster throughput all reduce waste.,JIT systems require managers to reduce variability which results in less waste.,Just-in-time Logistics,Figure 4-5 Inventory Hides the Problems,Figure 4-6 JIT and,Competitive Advantage,Just-in-time Logistics,JIT Partnership,It exists when a supplier and purchaser work together to remove waste and drive down costs.,Goals:elimination of unnecessary activities,in-plant inventory,in-transit inventory and poor suppliers,Just-in-time Logistics,JIT Layout,Build work cells for families of products,Include a large number of operations in a small area,Minimize distance,Design little space for inventory,Use u-shaped path,Just-in-time Logistics,Setup time can be reduced through preparation prior to shutdown and changeover.,Figure 4-7 An Example of Reduction in Setup Times,Just-in-time Logistics,Kanban,The system is designed so that each process in the production line pulls the right number and type of components at the right time.,By monitoring and maintaining the flow of materials,Kanban achieves precision in production.,Toyota was one of the first companies to apply the Kanban system.,Just-in-time Logistics,Figure 4-8 An Example of Kanban,Just-in-time Logistics,Number of Kanbans=(Demand in period Order Cycle time Safety stock)Batch size(or container quantity),Figure 4-9 A Pull Signal Card,Just-in-time Logistics,Lean Production,Specify work as to content,sequence,timing,and outcome,Direct customer-supplier connection,Simple and direct product and service flows,Scientific improvement at the lowest possible level of the organization,Increase employee commitment,The Agile Supply Chain Competing in Volatile Markets,Creation of responsive supply chains,Automation,Agility in less predictable environments,Market sensitive,Virtual supply chains of sharing info,Process integration,De-coupling point,Limited number of“strategic suppliers,Shared information,Connectivity,Thank You!,