Chapter15 - CHAPTER 15: JIT AND LEAN OPERATIONS Teaching...

Info iconThis preview shows pages 1–2. Sign up to view the full content.

View Full Document Right Arrow Icon
CHAPTER 15: JIT AND LEAN OPERATIONS Teaching Notes JIT seems to be one of the most popular subjects for the students. Some are a bit skeptical at first, but most are fascinated by this Japanese approach to repetitive production. It has been said by some Japanese that the system has its roots in Henry Ford’s assembly line. In fact, some interesting parallels and comparisons can be made between JIT systems and production lines. Perhaps the most challenging aspect of presenting JIT is where to start; that is, which elements to present first, and then, which order to present to remaining elements. It is important that students understand the difference between “romantic JIT” and “pragmatic JIT” because many times students can fall into the same trap that the senior management has fallen into. Students may also see JIT as a quick fix to many problems without realizing that there are no quick and easy solutions to these problems. It needs to be stressed to the students that it may take years to perfect a JIT system by implementing various techniques related to machine changeovers, layout design, product simplification, quality training and preventive maintenance. Answers to Discussion and Review Questions 1. Reduce downtime due to changeovers by reducing changeover time: JIT concentrates on reduction on setup times so that the lot size can be reduced. Of course, reduction of the lot size will result in reduction of the inventories and also increase productive time as a result of less time being allocated to changeovers. This approach is different than the traditional manufacturing approach where the main goal is to balance the trade-off between the changeover (setup) cost and cost of carrying inventory. Use preventive maintenance on key equipment to reduce breakdowns and downtime: Utilization of preventive maintenance can reduce breakdowns and downtime. Even though preventive maintenance is also part of traditional manufacturing systems, the manufacturing systems utilizing JIT will spend more money to ensure that breakdowns are avoided so that downtime is not experienced. Avoiding downtime will enable the company to reduce work- in-process (WIP) inventories because since we are not concerned about breakdowns, we do not need to maintain as much WIP, leading to reduced inventories and reduced waste. Cross train workers so they can help when bottlenecks occur or other workers are absent. Train workers to handle equipment adjustments and minor repairs: The name of the game is flexibility. Cross-training workers to handle different tasks will improve the flexibility of the system. The added flexibility will assist the company in a wide variety of ways. For example, if the cross-trained worker can assist a bottleneck work center, then the system throughput will increase and the work-in-process inventories can be reduced. If the trained workers can handle the minor repairs, then the repair crew does not have to be called. The ability of the worker to fix the equipment on-line not only improves the efficiency, but also
Background image of page 1

Info iconThis preview has intentionally blurred sections. Sign up to view the full version.

View Full DocumentRight Arrow Icon
Image of page 2
This is the end of the preview. Sign up to access the rest of the document.

Page1 / 10

Chapter15 - CHAPTER 15: JIT AND LEAN OPERATIONS Teaching...

This preview shows document pages 1 - 2. Sign up to view the full document.

View Full Document Right Arrow Icon
Ask a homework question - tutors are online