Information via the Kanban : Toyota Production System

These cards are in circulation in Toyota factories, between Toyota and other companies that work with him. And in the factories of companies that work together is. In this way, Kanban can convey information about the number of shots and the amount of production to achieve JIT production.
[caption id="attachment_821" align="alignleft" width="570" caption="Flow of 2 Kanban"][/caption]
For example we make the products A, B and C in a raft line. Spare parts needed to manufacture these products are a and b are produced by the previous engine line. Spare parts a and b are stored behind this line and Kanban production orders from this line attached to him.

JIT Implementation: JIT in the Process of Assembling Auto Parts

One example of JIT in the auto parts assembly process is to see to type sub-assembly is required from the previous process to achieve product line at the time required and the amount needed. If JIT is achieved throughout the company, the stocks that do not have the factory will be removed altogether. So that no material or warehouse inventory needed. Warehouse inventory costs will be reduced and capital turnover ratio will increase.

However, it is very difficult to achieve JIT in all processes for a product like a car when used arrangement of central planning (push system), which determines the production schedule and distribute to all processes simultaneously
Because of it, the Toyota system, we need to see the production flow in reverse, in other words, people of a certain process to go into the process earlier to take the necessary units in the required amount in the required amount of time required. Previous process was only manufacture enough units to replace units that have been taken. This system is called a pull system.

Customers generally do not want to know about how the production process is the most important is how the item can be shipped on schedule. There must be no delay

Learn More about 5s Management & Lean Manufacturing

Standardization of Mechanisms to Control the New Process and Hold the Gains

Design product to be produced to some extent will affect the production activities. Moreover, the design was made at the time of production is still going to produce long products. With the new product design that will certainly cause changes in manufacturing management system for example:

1. Setting machine
The machine that normally re-used should be setup to be the size, speed and so forth depending on the design of modified products
More and more design modifications of course the more the machine settings to be done. Even the possibility of adding machine tool production if the new design does not allow work by the old engine.

Unnecessary Capital Investment

Inappropriate initial planning will lead to wastage in the production process. Therefore, the design must be able to predict market manufacturing and processes that have the potential to change. Moreover, its relationship with the investment that is not necessary. This needs to be avoided remember to get optimum benefit should use the optimal investment as well. Some investments that should be eliminated, namely:

1. Construction of warehouses to store stocks Extra
2. The addition of extra labor to transport supplies to a new warehouse
3. Purchases of goods for each machine tool conveyances
4. The addition of employee stock controllers to handle the new warehouse
5. Addition Operator to repair the damaged stocks
6. The making process for managing requirements and the number of stocks indifferent types
7. The addition of people to deal with a computerized inventory control