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Unit 4 Just in Time Lean Production Notes

The document outlines key concepts of Lean Production and Just-In-Time (JIT) systems, emphasizing waste minimization and efficiency in manufacturing. It details types of waste, the pull system of production control, and techniques for reducing setup time for smaller batch sizes. Additionally, it highlights the importance of stable production operations and automation in maintaining quality and preventing errors.

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25 views2 pages

Unit 4 Just in Time Lean Production Notes

The document outlines key concepts of Lean Production and Just-In-Time (JIT) systems, emphasizing waste minimization and efficiency in manufacturing. It details types of waste, the pull system of production control, and techniques for reducing setup time for smaller batch sizes. Additionally, it highlights the importance of stable production operations and automation in maintaining quality and preventing errors.

Uploaded by

karanjuleyash1
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Unit 4: Just-In-Time and Lean

Production - Industrial Automation


1. Lean Production and Waste in Manufacturing
Lean production is a systematic method for waste minimization without sacrificing
productivity. It focuses on delivering value to the customer with fewer resources by
eliminating non-value-adding activities.

Types of Waste in Manufacturing (TIMWOOD):


- Transportation
- Inventory
- Motion
- Waiting
- Overproduction
- Overprocessing
- Defects

Flowchart: Lean Production Process


Customer Demand -> Value Stream Mapping -> Eliminate Waste -> Optimize Flow -> Pull
System -> Continuous Improvement

2. Just-In-Time (JIT) Production Systems


JIT is an inventory strategy to increase efficiency and reduce waste by receiving goods only
as they are needed.

Key Features:
- Reduced inventory
- Short lead times
- Improved product quality

Block Diagram: JIT Workflow


Supplier -> Delivery -> Production -> Customer

3. Pull System of Production Control


In a pull system, production is based on actual demand rather than forecasts. Items are
produced only when needed by the next process.

Advantages:
- Minimizes overproduction
- Reduces storage costs
- Enhances workflow
Flowchart: Pull System
Customer Order -> Schedule Production -> Manufacture -> Delivery

4. Setup Time Reduction for Smaller Batch Sizes


Reducing setup time allows for economical small batch production, enabling flexibility and
faster response to customer needs.

Techniques:
- SMED (Single-Minute Exchange of Dies)
- Standardized tools and procedures

Flowchart:
Old Setup Process -> Setup Time Analysis -> Implement SMED -> Reduced Setup Time

5. Stable and Reliable Production Operations and Automation


Stable production ensures consistent output, while automation helps maintain quality and
reduces manual errors.

Elements:
- Standard work
- Total Productive Maintenance (TPM)
- Predictive maintenance

Block Diagram:
Inputs -> Automated Production -> Monitoring -> Outputs

6. Automation - Stop the Process, Error Prevention, and Total Productive


Maintenance (TPM)
Automation allows processes to stop when errors occur, preventing defective products
from moving forward.

Error Prevention (Poka-Yoke):


- Devices or methods to avoid mistakes

TPM: A holistic approach to maintenance that involves all employees.

Flowchart:
Automation -> Detect Error -> Stop Process -> Notify Operator -> Fix Issue

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