2.3 Suggestions to Improve the Author(s) Point Based on the analysis by author and from their article, the seru production are very encourage and important to the company like Sony and Canon because they use this seru production to minimize their cost and increase their production. We agree with the author that is because the seru production can give many benefit to the organization such as it can reduce lead time, setup cost, work in process inventories, finished-product inventories, cost, required workforce, and floor space. Besides that, seru production also influences on the profits, product quality, and workforce motivation (Singh, 2017). In this suggestion, our suggestion will explain more about seru production. What the company must …show more content…
Yatai is a seru that have only one operator who is completely cross trained to assemble the product from beginning to finish without any aids. Stecke et al. (2012) says that the continuous evolution among yatai seru types in practice. When reconfiguring conveyor assembly lines, divisional seru should be formed first. With the advance of cross-training to get multi skilled operators, rotating seru can replace divisional seru, some of which can change into yatai. Besides that, the other seru designs, such as compound seru constructed by combining of the divisional seru, rotating seru, and/or yatai, and internally linked seru formed by interconnecting the three types of seru by a conveyor …show more content…
This situation means that the delivery system should get to provide a smooth flow of material among serus for the raw material and finished product. For the products that composed of many modules, different module must be processed in separate serus, and then assembled in a final assembly seru. In this situation, the delivery system of the internal linked of the seru production system is especially obvious needed. When make a well delivery system, the seru production system can achieve high performance. When want to determining the materials delivery plan, there are several comprehensive factors that including delivery time, delivery method, delivery route, delivery batch, and delivery frequency should be considered in an integrated
Due to improved technology and renovated management styles, organizations have the ability to meet the unique needs of individual customers (Daft, 2016, p. 271). This is referred to as mass customization and aims to provide the customer with the exact product they desire. Based on Joan Woodward’s research, organizations fall into three categories: small batch and unit production, large batch and mass production, and continuous process production (Daft, 2016, p. 262). She stated that as quantity increases, customization decreases due to the intensive time and resources needed to meet customers’ needs. However, due to processes such a lean manufacturing and improved technologies, organizations can now mass produce customized products. Mass production allows organizations to produce a larger line of products with a shortened response time, ultimately leading to an increased number of satisfied customers (Pollard, Chuo, & Lee, 2016, p. 102).
This report focuses on Toyota Motor Corporation, a Japanese automotive manufacturer which developed the concept of lean manufacturing to increase the efficiency of its production by reducing the stock holding level. The basis of Toyota Production System (TPS) is the sheer elimination of waste. TPS includes standardization of work, uninterrupted work flows, direct links between suppliers and customers, and continuous improvement based on the scientific method (Spear and Bowen, 1999). The four main concepts of TPS are Just in Time (JIT), automation, flexible workforce and capitalizing on workers suggestion. Also, Toyota uses the pull inventory control system where the orders come from the customers and the line reacts to the demand. Ohno (1988) formulated Kanban as a ‘medium to pull material from an upstream station and manage product flow’. This has given Toyota its competitive advantage through the years.
Achieving quality of conformance involved conform to specifications that involve providing customers with a quality product at the right price which accounts for the cost of materials. In order for a company to achieve and produce a successful product that customers want and need, it is vital that quality management and lean systems play front row. Quality management helps organizations to reduce waste and inventory. “Lean is about challenging the way things are done and opening our eyes to that waste and inefficiency” (Lean Benefits - Benefits of Lean, Why Lean is Important, 2015). Within each of these concepts are important tool and techniques that organizations can use to achieve a quality product. In this paper I will discuss “cost of quality” from the quality management side and “kaizen’s” from the lean system side, while discussing how each of these concepts are implemented into my own life or
Materials go to the factory → products come out and go to customers → companies do consumer research → companies do design of product + service and re-design → then it will affects three parts 1) materials; 2) processes; 3) product. As a result, it will improve the process.
Ownership and control of production ; vertically integrated manufacturing operation to enable its constant introducing of new items and also ensure short lead time
The basic premise for JIT is fairly simple: a company only produces an item when there is a need, or just-in-time for a company or individual to purchase it (Manoocherhi, 1988). The theory of JIT also accepts that there may be a need for an item at another work station and this would also create the need for production. Rather than utilizing the common practice of mass production and attempting to sell and distribute the products after they are created, JIT waits until there is a defined need that must be met. By doing this, JIT systems allow companies to decrease the level of production, decrease the necessary manpower hours utilized in mass production modes of supply, and eliminates the waste inherent in over-production. These techniques are especially effective for small companies, who are far less able to absorb the impact of unsold products. JIT has been shown to significantly impact reductions in overhead costs that reduce re-investments, and encourage stabilizing business practices(Manoocherhi, 1988).
The global supply chain variability is causing customer delivery delayed by around 40% and also experiencing quality problems that is introduced by the humidity difference between the locations of Chinese manufacturing plants. Moreover, it is taking much longer to deliver products, and the spare parts preventing any timely customer services. The goal is to come up with a faster product delivery and product cycle employing strategic and tactical changes that might improve supply chain problem and address the quality and increase customer
Above recommendations might improve the quality and reduce the defects & customer complaints. They might also help making the ramp up faster, improving the process and increasing the savings per product launch ---------> Maintain the high quality image, Increase in the market share. However there would be a trade-off on flexibility and creativity.
The chapter 2 literature review emphasized several approaches and key academic theories for the examination of role of integrated production system in the manufacturing industry to enhance the productivity. At this stage, it is crucial to expand knowledge and understanding of the philosophy and methodology of research. It is essential for the selection of most suitable methods to reach at the consistent and authentic conclusion according to the defined research objectives.
This is the activity carried out by organizations that own production sites, and their performance has a major impact on product cost, quality, speed of delivery and delivery reliability, and flexibility [8]. As it is quite an important part of the supply chain, production needs to be measured and continuously improved. Suitable metrics for the production level are as follows. Order lead-time, the total order cycle time, called order to delivery cycle time, refers to the time elapsed in between the receipt of customer order until the delivery of finished goods to the customer. The reduction in order cycle time leads to reduction in supply chain response time, and as such is an important performance measure and source of competitive advantage [9]. It directly interacts with customer service in determining competitiveness. Range of product and services: According to [8] a plant that manufactures a broad product range is likely to introduce new products more slowly than plants with a narrow product range. Plants that can manufacture a wide range of products are likely to perform less well in the areas of value added per employee, speed and delivery reliability. This clearly suggests that product range affects supply chain performance. Effectiveness of scheduling techniques is another important measure of supply chain effectiveness. Scheduling refers to the time or date on or by which
In order to facilitate the growth of assets a firm must control its assets by matching production and sales. To manage sales and productions, organizations “employ level production methods to smooth production schedules and use manpower and equipment efficiently at a lower cost” (Block & Hirt, ...
Operations – To work out the right layout and work flow process in the company. The manpower resource allocation is also critical in the situation on the right balance of resource to handle the production. If possible, adopt a hybrid model to handle the flexibility in the product nature, make both the production line being able to configure standard and customized so to reduce setup and changeover time and cope with the demands.
There are two main phases that are important in the movement of materials: material management and physical distribution. Materials management is the timely movement of raw materials, parts, and supplies. The physical distribution is the movement of the firm’s finished products to the customers. Both phases involve every stage of the process including storage. The ultimate goal of logistics is to coordinate all efforts of the company to maintain a cost effective flow of goods.
In manufacturing process there are different steps and jobs needs to be done in specific ways and time such as sourcing the parts we need in the production, make the items, and shipping it for the customers.
...change production planning and control, and supply and payment process, when firms provide customized products.