1. Introduction to Materials Management
Chapter 15 – Just-in-Time Manufacturing and Lean Production

2. Focus on Waste Reduction
Process and methods
Movement and storage of materials
Defects
Waiting time
Overproduction
Inventory

3. Poke-Yoke (Fail Safe) Design
Change the process or resources
Try to eliminate reliance on human experience and knowledge
Examples:
Color-coded parts
Templates
Use of counters on operations
Design plugs to only be inserted one way

4. Focus on Work Flow Flow manufacturing or work cells
Work toward flexibility
Process flexibility
Machine flexibility
Operator flexibility
Quick changeover with short setup times

5. Other Important Waste Reduction Actions
High product and process quality
Six Sigma quality approach
Total productive maintenance
Uninterrupted flow of material with uniform plant loading
Continuous process improvement

6. Focus on Suppliers Work toward supplier partnering Three key factors
Supplier selection
Supplier certification
Three key factors
Long-term commitment
Trust
Shared vision

7. Planning and Control for JIT
Forecasting and Production Planning not significantly different
Master Production Scheduling – focus on level and stable schedules
MRP – can be used to plan for supplier parts and for capacity

8. The Pull System
A system that reacts to usage and “pulls” replacement material
Contrast – MRP uses “push”
Limits inventory by having very small lots moved
Low cost because of setup reductions
One common approach – the Kanban system

9. Lean Production – the evolution of JIT
Value Stream Mapping – Process flow analysis focusing on reduction of non-value added activities
Kaizen – Structured approach to continuous process improvement
Takt time – The “heartbeat” of the system based on customer usage
5S approach – Focus on orderliness and cleanliness