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07+Pull_System - Different Production Systems Systems a...

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Unformatted text preview: Different Production Systems Systems a There are three basic production There control systems that are being practiced today practiced 1. Push Systems (MRP, MRP II) 2. Pull Systems (Kanban, Conwip) 3. Mixed production systems (pull/push Mixed and push/pull systems) Pull Systems of Production Pull a In order to achieve successful quality, In cost, and delivery ( customer satisfaction) in our manufacturing system, we must have three major systems in place: systems 1. 2. 3. Total Quality Control (or TQM) Total Productive Maintenance; and Setup Reduction(SMED) Single Card Kanban Control Single Material Flow 1 2 3 Order Signal (pull) WIP Operation 4 CONWIP Material Flow (push) 1 2 3 Order Signal (pull) WIP Operation 4 Push Production Systems Push a Many companies today plan and Many control their manufacturing operations with information system based on MRP (materials requirements planning) or its successor, MRP II (manufacturing resource planning). resource Push Production Systems Push MRP in general is called a “push MRP system” referring to the common image of in-process inventory being pushed from one work center to the next after completion of a work order. order. a Push systems plan production based Push on forecasted demand in batches. batches a Alternatively they are also called Alternatively a Push Production Systems Push Pull Production Systems Pull CONWIP CONWIP (CONstant Work In Process) is an alternative to Kanban where a new job is introduced into the line only if a job leaves the line. a The system operates based on the principle that a departing job out of the line sends a production card back to the beginning of the line to authorize the release of a new job. a CONWIP Material Flow (push) 1 2 3 Order Signal (pull) WIP Operation 4 CONWIP Estimating the card count (Little’s Estimating Formula) Formula) No. of Cards (WIP) = Demand x Cycle No. Time / Batch Size Time CONWIP a From a modeling perspective, a CONWIP system looks like a closed queuing network, in which customers (jobs) never leave the system but instead circulate around the network indefinitely. Kanban The card signaling system used in Toyota, which is considered the classic pull system for JIT manufacturing. a Common practice in pull production is to use standard-sized containers for holding and moving parts. a Necessary Conditions for Pull Production Systems 1. More planning and responsibility must reside in the hands More of supervisors and worker teams. of 2. The goal must be to produce to meet demand. 3. Focus and motivation is to reduce WIP. 4. TPM must be ongoing. 5. TQC must be ongoing (process monitor, SPC, source 5. inspection, poka-yoke, and autonomation) inspection, 6. Setup times must be small (SMED) 7. Leveled/mixed production must be used. 8. Flow production must be implemented. 8. Flow 9. Cooperative work attitudes and team work should be Cooperative ongoing. ongoing. ...
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