Outline

Basic concepts of the Toyota Production System

Simulating the Toyota Concepts

Benefits and applications

View of the Value stream map

How to apply it to your operation

Simcad Pro role in the transition to Lean Manufacturing

The dynamic value stream provides an efficient tool to validate existing or proposed design based on different product.

Kanban events and buffer sizes can be dynamically computed from the value stream.

Efficient reporting to generate best path, lean efficiencies, and OEE values.

Lean Methods

The Kanban

Required in process inventory to maintain high efficiency

The Supermarket

An inventory buffer used to reduce the customer and variability

Single Piece Flow paradigm

Components of a Non-Lean Environment

Traditional batch implementation

High inventory cost

Long production lead time, with high dependence on order variability

Excessive resource travel -- especially in the service sector

Reduced process and system efficiency

The Single Piece Flow

Ability to process one part one part at a time.

Requires a different processing paradigm to be successful.

Benefits of a single piece flow

Reduced inventory cost

Just-in-time production

Deterministic lead time

Increased process and system efficiency

Kanban

Used to implement a Pull system.

Defines the optimum inventory levels to place order from suppliers.

Suppliers and customers can be other departments within the same organization.

Optimizing Kanban provides:

Less Work in progress (WIP)

Improved lead time

Improved workflow efficiency

Kanban Implementation

Determining the optimum Kanban size is the key to a successful implementation.

With two or more Kanban systems...

While one kanban is being processed, another one is is being processed, another one is being filled by the supplier.

The second Kanban is requested when a predetermined condition occurs within the processing station.

The role of the Supermarket

Supermarkets are strategically located inventory within the operation.

Main use is to eliminate the effect of product variability in order to achieve:

A standard lead time

Have a predictable workflow

Reduce production risk

Reduce work in progress

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Edited by moderator Monday, June 15, 2015 12:53:33 PM(UTC)  | Reason: Not specified