Flexible Manufacturing JustInTime Manufacturing Copyright Texas Education Agency
Flexible Manufacturing Just-In-Time Manufacturing
Copyright © Texas Education Agency, 2017. These Materials are copyrighted © and trademarked ™ as the property of the Texas Education Agency (TEA) and may not be reproduced without the express written permission of TEA, except under the following conditions: 1) Texas public school districts, charter schools, and Education Service Centers may reproduce and use copies of the Materials and Related Materials for the districts’ and schools’ educational use without obtaining permission from TEA. 2) Residents of the state of Texas may reproduce and use copies of the Materials and Related Materials for individual personal use only, without obtaining written permission of TEA. 3) Any portion reproduced must be reproduced in its entirety and remain unedited, unaltered and unchanged in any way. 4) No monetary charge can be made for the reproduced materials or any document containing them; however, a reasonable charge to cover only the cost of reproduction and distribution may be charged. Private entities or persons located in Texas that are not Texas public school districts, Texas Education Service Centers, or Texas charter schools or any entity, whether public or private, educational or non-educational, located outside the state of Texas MUST obtain written approval from TEA and will be required to enter into a license agreement that may involve the payment of a licensing fee or a royalty. For information contact: Office of Copyrights, Trademarks, License Agreements, and Royalties, Texas Education Agency, 1701 N. Congress Ave. , Austin, TX 78701 -1494; phone 512 -463 -7004; email: copyrights@tea. state. tx. us. Copyright © Texas Education Agency, 2017. All rights reserved. 2
Just-in-Time Manufacturing Just-in-Time (JIT) manufacturing is a system of manufacturing where a company will purchase materials and produce a product when a customer orders that product. Copyright © Texas Education Agency, 2017. All rights reserved. 3
Just-in-Time Manufacturing The system works by having materials and parts delivered on an “as needed” basis. The materials that are needed are delivered directly to the assembly line. Copyright © Texas Education Agency, 2017. All rights reserved. 4
Just-in-Time Manufacturing This system of manufacturing has the customer in control of the rate of production. If a customer wants a standard supply of a product, the manufacturer can use this method to keep just enough products on hand to fill that order. Copyright © Texas Education Agency, 2017. All rights reserved. 5
Just-in-Time Manufacturing The use of Just-in-Time manufacturing has brought the cost of manufacturing down. The cost of large supplies of raw material is reduced and the cost of stocking finished products is also reduced. Copyright © Texas Education Agency, 2017. All rights reserved. 6
Just-in-Time Manufacturing The companies that use Just-in. Time manufacturing enable the workers to do more than just run a piece of equipment. The worker can make suggestions for improvement, check for quality, and are encouraged to learn more operations in the manufacturing operation. Copyright © Texas Education Agency, 2017. All rights reserved. 7
Just-in-Time Manufacturing A system of cards are used to keep track of the parts needed, or parts that are in production. These cards are called “kanban. ” Copyright © Texas Education Agency, 2017. All rights reserved. 8
Kanban > Means “signboard” in Japanese > In Just-in-Time manufacturing, it is a card or sign used to track products and supplies. Flexible Manufacturing Lab Standard Bolt ¼” -20 Threads 200 20 $0. 04 Supply cabinet #2 Copyright © Texas Education Agency, 2017. All rights reserved. 9
Kanban > The card tells the product name, size, number to order, price, safe stock, and storage area. > The card shown here has a picture of the product included. Part Name Flexible Manufacturing Lab Standard Bolt Size ¼” -20 Threads Photo Number to Reorder Price Safe Stock 200 20 $0. 04 Supply Cabinet #2 Storage Location Copyright © Texas Education Agency, 2017. All rights reserved. 10
Use of the Kanban > The card will be in or on the storage container. When the items in the container are used to the point of the “safe stock” (20 bolts) the product is restocked in the amount listed (200 bolts) Flexible Manufacturing Lab Standard Bolt ¼” -20 Threads 200 20 $0. 04 Supply Cabinet #2 Copyright © Texas Education Agency, 2017. All rights reserved. 11
Where did the number come from? > The safe number is the amount of the item needed to be on hand until a new order can be received > The numbers are monitored to keep the supply correct, so the line will not stop production Flexible Manufacturing Lab Standard Bolt ¼” -20 Threads 200 20 $0. 04 Supply Cabinet #2 Copyright © Texas Education Agency, 2017. All rights reserved. 12
Where did the number come from? > The reorder number is the amount of product that will be used over a given time, one day, or one production cycle. > The numbers are monitored to keep the supply correct, so the line will not stop production. Flexible Manufacturing Lab Standard Bolt ¼” -20 Threads 200 20 $0. 04 Supply Cabinet #2 Copyright © Texas Education Agency, 2017. All rights reserved. 13
Just-in-Time in A Flexible Lab > The use of the “kanban” card can keep supplies organized and in stock. > The sheet metal box is set up for a simple mass production project. > The box has three parts: • • • A box, a lid, and two pop rivets as hinges. Copyright © Texas Education Agency, 2017. All rights reserved. 14
Sheet Metal Box Copyright © Texas Education Agency, 2017. All rights reserved. 15
Box Plans Box Bottom Box Top Copyright © Texas Education Agency, 2017. All rights reserved. 16
1 7 Box Bottom Copyright © Texas Education Agency, 2017. All rights reserved. 17
Box Top Copyright © Texas Education Agency, 2017. All rights reserved. 18
SHEET METAL BOX BILL OF MATERIALS NAME Quality MATERIAL THICKNESS WIDTH LENGTH FINISH BOX 1 SHEET METAL 24 GAUGE 6¾ 12¾ PAINTED LID 1 SHEET METAL 24 GAUGE 5 ¹³/₁₆ 12 ¹³/₁₆ PAINTED POP RIVITS 2 METAL ⅛ DIAMETER ⅛” Long Copyright © Texas Education Agency, 2017. All rights reserved. 19
2 0 Box Kanbans Flexible Manufacturing Lab Box Lid Pop Rivets 24 Gauge Sheet Metal ⅛ Diameter x ⅛ Long 30 5 $0. 95 Supply Cabinet #1 30 5 70 10 $0. 75 Supply Cabinet #1 $0. 06 Supply Cabinet #2 Copyright © Texas Education Agency, 2017. All rights reserved. 20
Box Bottom Manufacturing Operations Operation Name Tool or Equipment Design layout Sheet metal bluing, scribe, and ruler Cutting bottom shape Aviation tin snips Fold long sides hems Box and pan brake Fold short sides to 90° Box and pan brake Fold long sides to 90° Box and pan brake Fold short side hems Box and pan brake Put in storage until assembly operation Storage area Copyright © Texas Education Agency, 2017. All rights reserved. 21
Box Top Manufacturing Operations Operation Name Tool or Equipment Design layout Sheet metal bluing, scribe and ruler Cutting bottom shape Aviation tin snips Fold long sides hems Box and pan brake Fold short sides to 90° Box and pan brake Fold long sides to 90° Box and pan brake Fold short side hems Box and pan brake Put in storage until assembly operation Storage area Copyright © Texas Education Agency, 2017. All rights reserved. 22
Box Assemble Manufacturing Operations Operation Name Tool or Equipment Layout hinge holes on lid Sheet metal bluing, scribe, and ruler Drilling or punch hinge holes Hand drill, ⅛ bit, and backer board Place lid on the box bottom Drilling hinge holes in the box bottom Hand drill, ⅛ bit, and backer board Install pop rivets Pop rivet tool Paint box Spray can of paint Put in storage until grading time Storage area Copyright © Texas Education Agency, 2017. All rights reserved. 23
Resources > Wright, R. T. (2004). Manufacturing and automation technology. Engineering Manufacturing Facilities (22, pp. 300 -301). Tinley Park, IL: Goodheart-Wilcox. > Wright, R. T. (2004). Manufacturing and automation technology. Computer Systems in Product Manufacturing (36, pp. 433 -434). Tinley Park, IL: Goodheart-Wilcox. Copyright © Texas Education Agency, 2017. All rights reserved. 24
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