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Q5. Explain the concept of JIT by using analogy of boy scouts troop. Stay Busy Individual resource Each machine M1 M5 M3 50 units/h 40 units/h 30 units/h M2 M4 45 units/h 35 units/h View the each resource individually - Each resource may try to keep its own maximum speed of the process (in order to reduce the cost) - If a worker doesn't have anything to do, let's find him something to do Dependency and Variability A chain is no stronger than its weakest link Dependency Whole system Entire production line Throughput M1 M2 M3 M4 M5 ? 50 units/h 45 units/h 30 units/h 35 units/h 40 units/h View the system or organization as a chain - Maximum speed of the process (dictate maximum throughput) is the speed of the slowest operation (bottleneck) - Any improvements will be wasted until this bottleneck is relieved or improved Dependency and Variability A chain is no stronger than its weakest link Variability Need to keep running M1 M2 M3 M4 M5 50 units/h 45 units/h 30 units/h) 35 units/h 40 units/h - 30 units/h - 30 units/h - 30 units/h - 30 units/h Failure, breakdown 20 units/h ? In order to keep bottleneck running, some amount of inventory (buffer) is needed in front of the bottleneck Drum-Buffer-Rope Drumbeat shows the output of constraints Stockpile of WIP inventory in front of constraints Sets the tempo for other Precaution to keep operations constraint running even Drum. Tells upstream operations what to when some problems in Buffer produce upstream operations Tells downstream operations what constraint to expect M1 M2 M3 M4 M5 Rope Limitation placed on production in upstream operation Precaution to stable amount of buffers in front of constraint Pull from drum, constraint Analogy of DBR; Troop of Boy Scouts Drum Buffer constraint M1 M2 M3 M4 M5 E Rope Drum Rope Buffer Analogy of DBR; Troop of Boy Scouts Troop of boy scouts is remarkably similar to a manufacturing system - The first boy walking on the road as receiving raw material into the system - This material is sequentially processed by the subsequent boys - The last boy releases the finished goods Spreading troops mean high inventory and closely packed troops mean lower inventory Raw materials Finished products Work-in-Process Inventory How can we prevent the troop from spreading? How to keep the group together while different member walks at different speed? How to keep the group together while different member walks at different speed? Tools which can limit the spreading to the length of the troop Drum Set the pace for the troop Rope Tie the members together Buffer Allow the following member to walk 1 How to keep the group together while different member walks at different speed? Q1: Who holds the drum in Ford's (push) system? Q2: Who holds the drum in Toyota's (pull) system? How to keep the group together while different member walks at different speed? Q1: Who holds the drum in Ford's (push) system? The drum dictates when raw materials are going to be released into the system The drum is held by the first member in Ford's system How to keep the group together while different member walks at different speed? Q2: Who holds the drum in Toyota's (pull) system? The drum dictates when raw materials are going to be released into the system The drum is held by the last member in Toyota's system Drum-Buffer-Rope Herbie Slowest 1 Drum-Buffer-Rope Herbie Slowest Drum Drum-Buffer-Rope Herbie Slowest Rope Drum Drum-Buffer-Rope Herbie Slowest fr Rope Drum Drum-Buffer-Rope Herbie Slowest Rope Buffer Drum Analogy of DBR; Troop of Boy Scouts -Tools which can limit the spreading to the length of the troop Drum Rope Management object Order or Signal Dictate the whole speed Buffer Stockpile of WIP to keep bottleneck running Raw materials Finished products Work-in-Process Inventory Rope Buffer Drum Q5. Explain the concept of JIT by using analogy of boy scouts troop. Stay Busy Individual resource Each machine M1 M5 M3 50 units/h 40 units/h 30 units/h M2 M4 45 units/h 35 units/h View the each resource individually - Each resource may try to keep its own maximum speed of the process (in order to reduce the cost) - If a worker doesn't have anything to do, let's find him something to do Dependency and Variability A chain is no stronger than its weakest link Dependency Whole system Entire production line Throughput M1 M2 M3 M4 M5 ? 50 units/h 45 units/h 30 units/h 35 units/h 40 units/h View the system or organization as a chain - Maximum speed of the process (dictate maximum throughput) is the speed of the slowest operation (bottleneck) - Any improvements will be wasted until this bottleneck is relieved or improved Dependency and Variability A chain is no stronger than its weakest link Variability Need to keep running M1 M2 M3 M4 M5 50 units/h 45 units/h 30 units/h) 35 units/h 40 units/h - 30 units/h - 30 units/h - 30 units/h - 30 units/h Failure, breakdown 20 units/h ? In order to keep bottleneck running, some amount of inventory (buffer) is needed in front of the bottleneck Drum-Buffer-Rope Drumbeat shows the output of constraints Stockpile of WIP inventory in front of constraints Sets the tempo for other Precaution to keep operations constraint running even Drum. Tells upstream operations what to when some problems in Buffer produce upstream operations Tells downstream operations what constraint to expect M1 M2 M3 M4 M5 Rope Limitation placed on production in upstream operation Precaution to stable amount of buffers in front of constraint Pull from drum, constraint Analogy of DBR; Troop of Boy Scouts Drum Buffer constraint M1 M2 M3 M4 M5 E Rope Drum Rope Buffer Analogy of DBR; Troop of Boy Scouts Troop of boy scouts is remarkably similar to a manufacturing system - The first boy walking on the road as receiving raw material into the system - This material is sequentially processed by the subsequent boys - The last boy releases the finished goods Spreading troops mean high inventory and closely packed troops mean lower inventory Raw materials Finished products Work-in-Process Inventory How can we prevent the troop from spreading? How to keep the group together while different member walks at different speed? How to keep the group together while different member walks at different speed? Tools which can limit the spreading to the length of the troop Drum Set the pace for the troop Rope Tie the members together Buffer Allow the following member to walk 1 How to keep the group together while different member walks at different speed? Q1: Who holds the drum in Ford's (push) system? Q2: Who holds the drum in Toyota's (pull) system? How to keep the group together while different member walks at different speed? Q1: Who holds the drum in Ford's (push) system? The drum dictates when raw materials are going to be released into the system The drum is held by the first member in Ford's system How to keep the group together while different member walks at different speed? Q2: Who holds the drum in Toyota's (pull) system? The drum dictates when raw materials are going to be released into the system The drum is held by the last member in Toyota's system Drum-Buffer-Rope Herbie Slowest 1 Drum-Buffer-Rope Herbie Slowest Drum Drum-Buffer-Rope Herbie Slowest Rope Drum Drum-Buffer-Rope Herbie Slowest fr Rope Drum Drum-Buffer-Rope Herbie Slowest Rope Buffer Drum Analogy of DBR; Troop of Boy Scouts -Tools which can limit the spreading to the length of the troop Drum Rope Management object Order or Signal Dictate the whole speed Buffer Stockpile of WIP to keep bottleneck running Raw materials Finished products Work-in-Process Inventory Rope Buffer Drum