Lean production method JIT

Author: Xiao Zhijun, Dang Xinmin
Publisher:
Publish Date: 2004-10-01
Features: Lean production methods require people to adopt a spirit of continuous improvement, with a focus on refinement and efficiency, to identify various wastes and defects in enterprise operations and management. Through employees' improvement activities, these are eliminated, continuously pursuing zero defects, zero waste, and rapid response.
Author Introduction:
Career History: Deputy Section Chief, China Railway Fourth Survey and Design Institute; Production Department Supervisor, Lihua Electric Factory (Hong Kong-invested); TPM Promotion Section Chief, Manufacturing Department Deputy, Ricoh (Shenzhen) Industrial Development Co., Ltd.; President of Ricoh Talent Development Association.
Current Position: General Manager, Shenzhen Hezong Resources Management Group.
Mr. Xiao Zhijun has been engaged in practical management of enterprise operations for over ten years, holding mid-to-senior management positions in state-owned, Hong Kong-invested, and Japanese companies. During his eight years at Ricoh, he served as the department manager for six departments (both on-site and planning) and ultimately became the highest Chinese supervisor in the on-site management department. He has traveled to Japan multiple times for training in TPM (Total Productive Maintenance) and Lean Production (JIT), gaining a comprehensive understanding and mastery of the essence of on-site management in Japanese enterprises. Mr. Xiao has applied theoretical knowledge to Ricoh's management practices, making significant contributions to its management enhancement, particularly in the TPM initiatives he led, which yielded remarkable results. Mr. Xiao Zhijun is the author of the best-selling domestic book on 5S, and he has published numerous articles in the "Enterprise Management" magazine. He has guided over 50 enterprises and is renowned in China as an expert in 5S management.
Some enterprises he has guided:
● Nokia (Suzhou) Telecommunications Co., Ltd.
● COSCO Southern China Container Manufacturing Co., Ltd.
● Shanghai Dairy Co., Ltd.
● Beijing Capital Astronautics Machinery Co., Ltd.
● Beijing Beiyuan Food Co., Ltd.
● China Great Wall Computer Co., Ltd. (Shenzhen)
● Fujian Heng An International Group Co., Ltd.
● Guangdong Mitsubishi Heavy Industry Air Conditioning Co., Ltd.
● Xi'an Astronautics Engine Co., Ltd.
● XJ Electric Co., Ltd.
Career History: Lecturer, Tarim University of Xinjiang; Manufacturing Section Chief, Unisplendour Electronic Co., Ltd. (Taiwan-invested); TPM Promotion Section Chief, Manufacturing Department Deputy, Ricoh (Shenzhen) Industrial Development Co., Ltd.
Current Position: Deputy General Manager, Shenzhen 3A Management Consulting Co., Ltd.
Mr. Dang Xinmin has been involved in university education and practical enterprise management for many years, holding mid-to-senior management positions in joint-venture and Japanese companies. During his tenure as TPM Promotion Section Chief and Manufacturing Department Deputy at Ricoh, he built top-tier on-site management through the implementation of 5S, TPM, and MQM. Additionally, Mr. Dang is proficient in modern quality management techniques and has established new quality control systems, such as quality prediction and new product completion evaluation, to rapidly stabilize product quality. Due to his outstanding management achievements, he has been invited to participate in and deliver keynote speeches at management exchange conferences in Japan, the U.S., the UK, France, and China. Mr. Dang has also traveled abroad for modern management training and has visited many renowned enterprises (Toyota, NEC, Epson, IBM) and guided over 30 enterprises, including Ricoh Fax Machine (Shanghai).
Some enterprises he has guided:
● Ricoh Fax Machine (Shanghai) Co., Ltd.
● Sany Heavy Industry Co., Ltd.
● Guangzhou Copier Factory
● Hefei 38th Research Institute
● Kunming Jinghua Optical Co., Ltd.
● Geely Auto Manufacturing Co., Ltd.
● Fujian Xuejin Beer Co., Ltd.
● Tianjin Communication Broadcasting Group Co., Ltd.
● Guangdong Float Glass Co., Ltd.
● Xi'an 210th Research Institute
Table of Contents:
Preface
Chapter 1 What Is Lean Production Method?
Section 1 Overview of Lean Production Method
1. What Is Lean Production Method?
2. Comparison of Manual, Mass Production, and Lean Production Methods
3. Expected Outcomes of Implementing Lean Production Method
4. Customer-Centric Manufacturing Philosophy
5. Lean Production System
Section 2 Basics of Lean Production Method
1. Background of Lean Production Method
2. Goals of Lean Production Method
3. Basic Tools of Lean Production Method
4. Management Tools for Achieving Lean Production
Chapter 2 Identifying Wastes in Management
Section 1 Continuous Improvement in Business Operations
1. Cost-Center Business Perspective
2. Price-Center Business Perspective
3. Profit-Center Business Perspective
Section 2 Inefficient Management Status
1. Common Defects
2. 7 Common Wastes in Factories
3. 12 Common Motion Wastes
Chapter 3 Production Planning and Kanban Management
Section 1 Lean Production in Manufacturing
1. Push Control System vs. Pull Control System
2. Characteristics of Lean Production Planning
3. Pursuit of Production Management Indicators in Push and Pull Systems
4. Types of Production Plans
Section 2 Rules for Making Production Plans
1. Steps to Develop Rolling Production Plans
2. Traditional "Game Rules" for Rolling Production Plan Development
3. New "Game Rules" for Rolling Production Plan Development
4. Master Production Schedule, Production Orders, and Process Scheduling
Section 3 Methods for Implementing Production Orders
1. Introduction to MRP
2. Analysis of Advantages and Disadvantages of MRP
Section 4 Kanban Management
1. Kanban Management as a Key Tool for Lean Production
2. Functions of Kanban
3. Types and Uses of Kanban
4. Methods of Using Kanban
5. Process of Organizing Production with Kanban
6. Achieving JIT (Just-In-Time, Right-Quantity, Right-Item Production)
Chapter 4 Lean Production and Just-In-Time Procurement
1. Purpose of JIT Procurement
2. Characteristics of JIT Procurement
3. Common Methods of JIT Procurement
Chapter 5 Lean Production and Product Development
Section 1 Lean Product Planning
1. Key Decisions in Planning Stage
2. Concept of Design and Development
Section 2 Seven Projects in Design and Development
1. Concurrent Development
2. Project Management
3. Completion Evaluation
4. Quality Prediction
5. Design Evaluation and Application of Statistical Techniques
6. Modular Design
7. Application of Computer Technology
Chapter 6 Lean Production and Quality Assurance
1. Quality as the Guarantee of Lean Production
2. Five Elements of Quality Assurance
3. Shifting from Post-Event Control to Pre-Event Prevention
4. Lean Production in Promoting Quality Improvement
5. Equipment Maintenance
6. Quality Goals of Lean Production
Chapter 7 Production Process Optimization
Section 1 Production Synchronization
1. Individual Efficiency vs. Overall Efficiency
2. One-Piece Flow Production
3. Shortening Setup Times
4. Determining Production Takt Time
Section 2 Production Balancing
1. Why Balance Production
2. How to Achieve Mixed Production
3. Case Studies in Balanced Production
Chapter 8 Flexible Production Methods
Section 1 The Necessity of Flexible Production
1. Two Meanings of Flexible Production
2. Accelerating All Departmental Work as a Prerequisite for Flexible Production
3. Flexible Production Structure in Enterprise Operations
Section 2 Flexible Workforce
1. Flexible Workforce
2. Prerequisites for Streamlining Labor
3. U-Shaped Equipment Layout
4. Key Points of Implementing U-Shaped Layout
5. Methods for Developing Multi-Skilled Workers
Chapter 9 Introduction and Case Studies of Lean Production Method
Section 1 Key Points for Implementing Lean Production Method
1. Training and Mindset Transformation
2. Key Implementation Points
3. Lean Production Case Studies
Section 2 Lean Production Case Studies
Case 1 Jialing Industrial Co., Ltd.
Case 2 Impact of Lean Production Method on Western Enterprises
Case 3 Toyota Company
Case 4 Matsushita Electric Company
Case 5 NGK Spark Plug Factory
Case 6 Canon Camera Factory