CHUYEN E: SAN XUAT THEO JIT

Thi lng 42 tiet (03 tiet/ tuan) Lp QLCN: Hoc ky II Nam hoc 11/12 Qui nh: - Bai tap thc te theo nhom (07 SV): 20% - Bai tap ca nhan: 20% - Thi cuoi ky: 60%

Qui nh ve bai tap nhom:

Muc ch: nang cao kien thc thc te, ky nang lam viec theo nhom, ky nang trnh bay,.. Cac bc tien hanh: Giai oan 1: 03 tuan au: xac nh cac thanh vien trong nhom (t 5 7 SV) va ten cong ty se lam lam bai tap Giai oan 2: 06 tuan: anh gia cac thuan li va kho khan cua cong ty neu ap dung Lean va JIT. Giai oan 3: 04 tuan: cac nhom trnh bay ket qua anh gia
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Qui nh ve bai tap ca nhan :

Muc ch: Nang cao k nang tm tai lieu, kha nang phan tch, so sanh, ap dung thc te (neu co the) va viet bao cao Cac bc tien hanh: Giai oan 1: 04 tuan:Tm cac tai lieu t cac nguon co the lien quan ti Lean/hoac JIT (nop danh sach cac tai lieu tm c) Giai oan 2: 02 tuan: chuan b e cng bai viet (nop e cng) Giai oan 3: 04 tuan: oc tai lieu, phan tch so sanh, ket luan va viet bao cao 3 (khong 6 trang)

NOI DUNG: PHN I:

CHNG 1: GII THIEU VE JIT 1. Nguon goc cua JIT 2. Muc tieu cua JIT 3. Nen tang cua JIT 4. Li ch cua JIT CHNG 2: HE THONG KABAN TRONG JIT 1. Gii thieu ve Kaban 2. Khai niem ve Kaban 3. Chc nang cua Kaban 4. Cac loai Kaban 5. Cac nguyen tac cua Kaban 6. u nhc iem cua Kaban CHNG 3: NG DUNG JIT 1. ng dung cua JIT trong kiem soat nguyen vat lieu 2. ng dung cua JIT trong san xuat/che tao
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CHNG 4: NHNG THAY OI TRC KHI NG DUNG JIT Thay oi nguyen tac hanh chnh truyen thong Thay oi cach quan ly Canh tranh bang rut ngan thi gian CHNG 5: CAI TIEN LIEN TUC Tao moi trng chap nhan thay oi Thiet lap MRP/JIT trong toan cong ty Phat trien cac muc tieu toan dien o lng Cai tien lien tuc CHNG 6: CAC HAN CHE CUA JIT
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PHN II: LEAN MANUFACTURING

CHNG 7: GII THIEU VE LEAN CHNG 8: CAN BANG CHUYEN

TAI LIEU THAM KHAO

John N. Petroff, Handbook of MRP II and JIT Strategies for Total Manufacturing Control, Prentice Hall, 1993 Krajewski/Ritzman, Operations Management Strategy and Analysis, 2nd Ed., Addisonwesley, 1990 Robert Johnston, Stuart Chambers, Cases in Operations Management, 2nd Ed., Financial Times, Pitman Publishing, 1997
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1.

2.

3.

4. Yasuhiro Monden, Toyota Production System, an Integrated Approach to Just-In-Time. Third Edition, EMP 1998 5. James P. Womark, Daniel T. Jones, Lean Thinking, Banish Waste And Create Wealth in Your Corporation. Free Press, 2003 6. Dennis P. Hobbs, Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer. J. Ross Publishing @ 2004
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JUST IN TIME (JIT)

Phan 1
GII THIEU
I. II. III. IV.

Nguon goc cua JIT Muc tieu cua JIT Nen tang cua JIT Li ch cua JIT

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1. Nguon goc cua JIT

JIT la g?: JIT la: ch cung cap cac san pham vi lng can thiet trong thi gian can thiet. Cong ty phai thc hien JIT v: - Phai san xuat vi so lng nho(moi loai) va vi nhieu loai san pham ket hp Thiet lap he thong san xuat nhieu hang, co so lng nho co nang suat cao (gap 8 lan) Va vi chi ph thap hn. 11

2. Muc

tieu cua JIT

Muc tieu quan trong nhat cua JIT la tao ra c he thong can bang e at muc tieu tren can cac muc tieu ho tr sau: Han che gian oan trong van hanh. Thc hien he thong san xuat linh hoat. Giam thi gian hieu chnh (may va chuyen) va thi gian gia cong. Toi thieu hoa hang ton kho. Loai bo cac lang ph.
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Muc tieu cua JIT (tt.)

Da vao cac nen tang sau: Thiet ke san pham.(v sao?) Thiet ke qua trnh. Hoach nh va kiem soat san xuat. Cac yeu to ve to chc nhan s.

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3. Cac nen tang cua he thong JIT

3.1 Thiet ke san pham Co gang ap dung rong rai viec tieu chuan hoa va thong nhat hoa cac san pham, cac cum cua cac san pham & chi tiet. Nham nang cao tnh hang loat trong san xuat, rut ngan thi gian SX, giam thi gian cho cong tac chuan b ky thuat giam chi ph. Co 03 yeu to chnh trong thiet ke cho JIT:
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Chuan hoa chi tiet cua san pham: - Nham giam thi gian ao tao cong nhan va cac ph ton. - Viec nhap hang, chuyen giao va kiem soat chat lng tr nen quen thuoc. - Giup viec cai tien lien tuc c thuan li hn. - Tang kha nang ap dung qua trnh gia cong chuan.

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Thiet ke mau chuan: cac cum chi tiet san pham c xem gan nh ch thiet ke cho tng cum. ieu nay lam giam ang ke so chi tiet san pham c thiet ke, lam n gian hoa khau nhap vat lieu.

San pham A San pham B San pham C

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Chat lng thiet ke: Chat lng trong thiet ke kem se tao ra s gian oan san xuat va lam pha v he thong JIT.

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3.2 Thiet ke qua trnh

San xuat loat nho (small lot production) Li ch cua san xuat loat nho: - Giam ton kho, chi ph van chuyen thap. - Giam dien tch khong gian tr hang. - t tai che neu co khuyet tat xay ra. - Cac van e tr nen ro rang nen de x ly hn. - Gia tang tnh linh hoat trong san xuat. De dang cho van hanh ong bo. Nhc iem:Ton nhieu thi gian hieu chnh

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Giam thi gian hieu chnh

1.

2.

3. 4.

Hieu chnh trong c tien hanh khi may a ngng han. Hieu chnh ngoai th ngc lai, ta co the thc hien khi may ang chay. Tach rieng hieu chnh trong ra khoi hieu chnh ngoai Chuyen hieu chnh trong thanh hieu chnh ngoai cang nhieu cang tot, bang cach am bao cac ieu kien tac nghiep nh tap hp dung cu, chuan b o ga lap hieu chnh Tat ca eu c chuan b trc. Sap xep hp ly cong viec hieu chnh. Thc hien viec hieu chnh song hanh bang cach tang cng nhan s cho viec ieu chnh e rut ngan thi gian, hoac giao nhiem vu hieu chnh
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Sap xep mat bang san xuat han che san pham d dang

Cac chi tiet san pham se di chuyen tng n v (mot cach ly tng) hoac theo tng lo t bc cong viec nay sang bc cong viec khac theo mot lo trnh nh san va theo mot hng nhat nh t khi a nguyen lieu vao en khi hoan tat san pham. Li ch quan trong cua bo tr mat bang hp ly la giam thi gian di chuyen, tan dung toi a trang thiet b va lao ong. Viec ket hp nang cao hieu qua bo tr mat bang va phng thc san xuat loat nho se han che san pham d dang, du co gia cong nhieu loai chi tiet san pham vi thi gian nh mc khac nhau Do o nang cao tnh linh hoat trong san xuat, ap ng nhu cau thay oi san pham mau ma theo tng n hang. 22

Cai tien chat lng

CHAT LNG LA U TIEN HANG AU Giam ty le phe pham Li nhuan tang Giam chi ph bao dng GOODWILL tang Giam chi ph kiem tra

OI

MI
NHAN THC

NH HNG VAO NGI TIEU DUNG Thc hien chu trnh Deming MPPC Th trng Thiet ke San xuat Ngi tieu dung

CON NGI YEU TO SO MOT TRONG QUAN TR ao tao boi dng, cap nhat hoa kien thc. oi mi t duy va triet ly quan tr. T quan tr cong viec cua mnh. Tinh than to nhom va cong ong.

QUAN TR THEO CHC NANG QUAN TR CHEO Xay dng cac Hoi ong chc nang.

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Hnh : cac yeu to chi ph, so lng, chat lng, va con ngi c cai tien trong he thong san xuat Toyota
Gia tang doanh thu Gia tang li nhuan Giam chi ph bang cac loai bo lang ph Cat giam ton kho Kiem tra so lng ap ng nhu cau thay oi San xuat JIT He thong Kanban Lao ong linh hoat Cat giam lao ong He thong kiem tra QC Ton trong con ngi ay manh tinh than lao ong

Bao am chat lng

San xuat nhp nhang Giam thi gian san xuat chnh San xuat theo lo nho San xuat tng bo phan trong day chuyen can bang

He thong Jikoda Quan ly chc nang

Thay oi trong qua trnh san xuat chuan hoa

Giam thi gian chuan b

Cach bo tr mat bang

Cong nhan a nang

San xuat chuan hoa

Cai tien hoat ong bang nhom nho

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He thong Jikoda (Autonomation)

Cac iem ac trng cua Jikoda c hoan tat chu yeu thong qua cac phng tien t ong ngng. Ngng van hanh khi san xuat ra bo chi tiet kem chat lng, Ngng san xuat khi u so lng can thiet, Ngng san xuat khi ket thuc mot chu ky van hanh.
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He thong Jikoda (Autonomation)

Ba ac trng cua Jikoda: - Ngan nga san xuat tha - Ngan nga san xuat hang kem chat lng - Kiem soat cac s co mot cach de dang

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Ton kho thap

He thong JIT c thiet ke nham toi thieu hoa ton kho, v ton kho la nhng nguyen nhan lam gia tang chi ph, mat bang va nhng bat li khac na.

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3.3 Hoach nh va kiem soat san xuat

5 yeu to ac biet quan trong cho he thong JIT: 1) San xuat eu an: - Duy tr mc san xuat eu an nham de dang ap ng cac yeu cau san xuat (thay oi) tren day chuyen lap rap san pham - e thc hien san xuat eu an, ta phai biet lng hang(d bao) can san xuat theo ke hoach. - Ke hoach san xuat phai c lap cu the cho tng thang, tham ch cho tng 10 29 ngay hoac theo tng n hang

Thay oi loai san pham san xuat ch can biet trc 01 buoi Mot n hang ln phai c chia nho va eu cho suot thi gian thc hien va c san xuat ket hp ong thi vi cac san pham khac ngay trong cung mot ngay. Viec ket hp cac san pham phai do bo phan rap chi phoi => Lam cho san xuat on nh, t ton kho va theo he thong san xuat keo

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V du
Neu hang thang mot cong ty giay d bao nhu cau 3 loai san pham la: A la 120.000 n v, B la 280.000 n v va C la 240.000 n v Nen san xuat nh the nao theo ke hoach san xuat eu an cua he thong JIT? (Moi thang co 4 tuan hoac 30 ngay). Giai: Cuoi cung cong ty len ke hoach san xuat tuan t nh sau: Neu nhu cau hang tuan, eu an, cong ty san xuat nh sau: San pham Tuan 1 Tuan 2 Tuan 3 Tuan 4 A 30000 30000 30000 30000 B 70000 70000 70000 70000 C 60000 60000 60000 60000 Neu nhu cau hang ngay, eu an, cong ty san xuat nh sau: San pham Ngay 1 Ngay 30 A 4000 sp 4000 sp B 9000 sp 9000 sp C 8000 sp 8000 sp Neu san xuat theo th t A=>B=>C se lam giam tnh linh hoat

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2. He thong keo

Cong nhan bo phan sau en bo phan trc ch lay u so mnh can(u e lam) => khi o bo phan trc mi c san xuat them ung theo so lng tac nghiep yeu cau - khong c san xuat d => dung he thong Kaban

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Push Production Systems

make to stock

production decisions are based on forecasts of demand appropriate when uncertainty about demand is low generally not compatible with JIT

Wiley 2010

Pull Production Systems

Make to order work is triggered by order from external customer, or internal customer (e.g. last station in line) generally compatible with JIT

Wiley 2010

The Pull System

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3. He thong kiem soat san xuat Kanban

u iem: 1. Thc hien he thong kiem soat khong can ien toan hoa, tranh c cac ph ton ln. 2. Giup thu nhan thong tin nhanh chong va chnh xac da tren c s thc te. T o lap bieu tong hp d kien phan anh chnh xac cac thay oi. Chc nang: 1. Gi i tc thi thi gian bieu san xuat 2. ap ng linh ong cac thay oi cac yeu to SX => Cong viec se de dang hn, chi ph thap hn
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4. S kiem soat bang mat thng

a)Ky thuat Andon: Andon la mot bien bao hieu c dng len tai mot tram lam viec hay c treo tren mot day chuyen san xuat bang cac en mau khac nhau, cho biet cong viec ang dien tien bnh thng hoac ang cham tre, hoac a ngng. Thong thng: en xanh ngha la cong viec van hanh bnh thng, en vang ngha la bieu hien cham tre can cai tien, va en o la bao hieu roi loan can co hanh ong tc khac. 37

b. a ch( au?): Cac tram cong viec, khu vc tr hang, cac khu khac trong xng eu c ghi bang hieu ro rang. Phng phap nay giup cho Kanban i ung tuyen gia cac quy trnh.

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c. Bang ghi chu ky thi gian Tai cac khu vc lam viec eu co cac bang bieu ghi ro chu ky thi gian cua qua trnh hay cua day chuyen nham giup cho cong nhan c lng c toc o tien trien cua mnh

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5. Quan he vi nha cung cap

Li ch cua JIT trong moi quan he vi nha cung cap: cac nhu cau c bao am, on nh; ap ng kp thi nhng thay oi ve so lng, thiet ke; s ho tr ve cong nghe, thiet b va quan tr. Khuynh hng cua nha cung cap: 1. ong gan khach hang, a ban cua nha san xuat. 2. Bo tr cac kho hang gan ni san xuat; tham ch cac nha cung cap khac nhau hp lai dung chung mot kho. 3. S dung cac kho hang nho e cung cap cac chi tiet thng xuyen. 4. S dung cac container tieu chuan hoa va cap hang theo ung ke hoach nh trc. 5. S dung he thong trung gian co uy tn nhan trach nhiem giao hang thng xuyen cho nha san xuat. Nh vay giam c thu tuc giay t, nhat la oi vi hang hoa xuat nhap khau, va han che viec kiem tra chat lng khi giao hang.
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6. Cac yeu to ve to chc nhan s

1.Tan dung kha nang cong nhan Nhan lc la nguon tai nguyen co gia tr nhat, JIT yeu cau: Tach cong nhan ra khoi thiet b bang cach ch nh mot cong nhan phu trach nhieu may khac nhau hoac tren cung mot loai may co the thc hien nhieu bc cong viec khac nhau(tranh n ieu). Viec nay oi hoi huan luyen cong nhan thanh cong nhan a nang. Tap trung cac thiet b may moc giong nhau theo tng khu vc va bo tr cong nhan theo th t cua quy trnh cong nghe doc theo cac ben cua day chuyen.
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a)

b)

Cong ty phai: Quan tam en s an toan cua cong nhan Ton trong trach nhiem va quyen han cua cong nhan: Bat c cong nhan nao cung c quyen ngng day chuyen ni anh ta ang lam viec. Khi cong nhan phat hien co mot bat thng trong cho van hanh. Chac chan ngng day chuyen se giup xac nh c sai sot, nhng ieu quan trong hn la tao cho cong nhan y ngh lam chu c cong viec, lam chu c 42

Quan oc phan xng hay oc cong c phep quyet nh lam them gi, phan phoi cong viec. Cac cong nhan tren day chuyen cung c thong bao ro cac phan viec nao cua ho c u tien va tnh trang san xuat hien tai. Cong nhan c khuyen khch tham gia vao no lc cai tien. Moi cong nhan eu co quyen x ly cac lang ph khi gap phai.
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2. Cai tien lien tuc

Cac nguyen tac trong cai tien lien tuc : Nhn nhan cai tien la khong co gii han. Khong bao gi thoa man vi thanh qua at c. khong bao gi chap nhan khai niem hoan hao, luon phat hien sai sot va cai tien. Tm thay s cai tien trong thc te hn la mua s cai tien. Lam viec trong tinh than ong oi co ton trong y kien ca nhan. Chap nhan th thach.
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3. Nhan manh vai tro cua nha quan ly cap trung

Bon chc nang chu yeu cua cap quan ly trung gian nh sau: Hng dan lam viec Phng phap lam viec Quan ly Cac quan he gia ngi vi nhau

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Muc tieu toi quan trong

Dong lien tuc, ong bo

Bang tom tat cac muc tieu

va nen tang chu yeu cua JIT

Muc tieu ho tr

* Han che gian oan *Giam thi gian ieu * Lam cho he thong chnh va thi gian linh hoat gia cong

*Loai bo lang ph *Toi thieu hoa ton kho

1. Thiet ke san pham Chi tiet san pham chuan Thiet ke mau Thiet ke chat lng

2. Thiet ke qua trnh San xuat loat nho Giam thi gian hieu chnh Bo tr mat bang san xuat Cai tien chat lng Ton kho thap

3. Hoach nh & kiem soat san xuat San xuat eu an He thong keo He thong kiem soat Kanban Kiem soat bang mat thng Quan he vi nha cung cap

4. To chc nhan s Tan dung kha nang cong nhan Cai tien lien tuc Vai tro cua nha quan ly cap trung

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4. Li ch cua JIT

Giam mc ton kho nguyen vat lieu, ban thanh pham cung nh thanh pham. Giam cac yeu cau ve khong gian Tang chat lng san pham, giam phe pham. Giam thi gian san xuat chu yeu M rong tnh linh hoat trong thay oi san pham Dong san xuat lien tuc vi viec giai quyet c cac van e ve chat lng, thi gian nh mc ngan hn va cong nhan a nang. Tan dung trang thiet b va nang cao nang suat Tham gia cua cong nhan trong giai quyet van e Tao moi quan he tot vi nha cung cap.

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Tho lun
JIT ph hp loai hnh sn xut no ? Ko ph hp loai hnh sn xut no ? JIT trong dich vu

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