(jit) principles and systematic layout planning as tools to improve ...

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BIODATA OF CHE RAZALI CHE ISMAIL Che Razali bin Che Ismail is a consultant at National Productivity Corporation, Petaling Jaya. He obtained his Master of Science in Manufacturing Systems Engineering and Management at University of Bradford, UK in 1997. His first degree is Bachelor of Science in Civil Engineering from University of Nebraska Omaha, USA in 1988. His main areas of expertise are ISO 9000, 5S, 7QC Tools, Process Q and JIT. Previously he was a Civii Engineer and also Chief Designer Engineer in two companies in USA and Malaysia. 30
JUST-IN-TIME (JIT) PRINCIPLES AND SYSTEMATIC LAYOUT PLANNING AS TOOLS TO IMPROVE PRODUCTIVITY AND QUALITY (P&Q) By Che Razali Che Ismail ABSTRACT: This article discusses a case study on a factory called Birkbys Plastics Limited, United Kingdom. The objective of the study was to analyse the current production system in a manufacturing cell called Gemini with regards to people, machines, tools and material. Based on the data collected, several new layouts were suggested to improve the efficiency and utilisation of people and machines. Several Just-in-Time (JIT) elements were also suggested to eliminate waste while improving the present production and quality system. Comparison was made between the existing and the proposed layout of the cell. This is to show the advantages of the new layout. Cost analysis was also carried out to determine the expenses and savings. INTRODUCTION Manufacturing industries have had an interest in the Just-in-Time (JIT) philosophy for the past two decades due to the significant reduction in costs and inventory, improvement in quality of goods produced, increased productivity and other manufacturing improvements. JIT concepts can be used to reduce manufacturing lead times, increase utilisation and efficiency of workers and equipment, reduce work-in- progress, increase work in progress, inventory turnover, reduce raw materials, improve quality, reduce finished goods inventory, reduce production space requirements, increase flexibility in changing production mix, reduce scrap and increase productivity [Schonberger (1982), Zipkin (1991)]. JIT philosophy, also known as 'Pull System' is a concept where goods are manufactured when they are needed at the right quantity without wastage. JIT has attracted a massive interest in the East and the West and has been strongly recommended by Monden (1983), Schonberger (1982), Shingo 31
Page 1 and 2: PRODUKTIVm SUPPLIER DEVELOPMENT IN
Page 3 and 4: pRODUKnvm PENASIHAT Tuan Haji Ismai
Page 5 and 6: BIODATA OF RALIMOHD NOR Rali Mohd N
Page 7 and 8: The supplier development concept ha
Page 9 and 10: 4. SCOPE AND LIMITATIONS OF THE STU
Page 11 and 12: Annual Master Plan (AMP) Long Range
Page 13 and 14: 6.2 SELECTION OF SUPPLIERS The supp
Page 15 and 16: Cases/ Company Company A Company B
Page 17 and 18: Proton inherited the automobile tec
Page 19 and 20: such as of technical know-how, supp
Page 21 and 22: A point worth noting in the Malaysi
Page 23 and 24: finished products. In short, the JI
Page 25 and 26: Car Assembly Production © Reverse
Page 27 and 28: Appendix 1: Cost Breakdown of Proto
Page 29 and 30: Departments Procurement & Vendor De
Page 31 and 32: Average ration of share parts Produ
Page 33: Sako, M, (1992), "Prices, Quality a
Page 37 and 38: UJ UJ Figure 1.1: Existing Layout o
Page 39 and 40: At the University of Bradford (UOB)
Page 41 and 42: Presently, tools for all the machin
Page 43 and 44: 2.3 Proposed Layout Improvement No.
Page 45 and 46: MC NO. Al A2 A4 A5 A6 47 A8 A9 A10
Page 47 and 48: Controller who plans the production
Page 49 and 50: Figure A4r i > \ 2 \l C c / ) 1.8 P
Page 51 and 52: Raw Mat. Store Tool Storage Area To
Page 53 and 54: above, the forklift is not required
Page 55 and 56: The remaining of the production los
Page 57 and 58: 4.10 Set-up Time Reduction Saving T
Page 59 and 60: TABLE 2.2 Standard Price List for P
Page 61 and 62: 5.3 Project Achievements The propos
Page 63 and 64: REFERENCES 1. Alaya, S.E.B.H., Elim
Page 65 and 66: 27. Monden Y., Toyota Production Sy
Page 67 and 68: BIODATA OF ALIAS RADAM Alias Radam
Page 69 and 70: an investment-driven strategy towar
Page 71 and 72: country's dependence on chemical im
Page 73 and 74: distance ratio: OB/OF in order to m
Page 75 and 76: productivity growth in the context
Page 77 and 78: egistered the largest increase in m
Page 79 and 80: Productivity Growth Measurement Two
Page 81 and 82: CONCLUSION Chemical related industr
Page 83 and 84: Chambers, R. (1988) Applied Product
Page 85 and 86:
Maisom, A. (1995) "Total Factor Pro
Page 87 and 88:
TABLE 1 TYend in Production, Employ
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MIC Code 35111 35119 35120 35130 35
Page 91 and 92:
Year 1983 1984 1985 1986 1987 1988
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TABLE 8 Malmquist Index, Technical
Page 95 and 96:
FIGURE 2 Malmquist Index and Produc
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BIODATA OF DR. SHARIFUDDIN ZAINUDDI
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However, the extremely few existing
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SERVICE QUALITY MODEL According to
Page 103 and 104:
Word of Mouth Communications CONSUM
Page 105 and 106:
any point in the ZoT might be consi
Page 107 and 108:
who pay a nominal fee and received
Page 109 and 110:
RESEARCH FINDINGS Hypothesis la: Ac
Page 111 and 112:
TABLE 2 Manova and Paired Sample T-
Page 113 and 114:
It could be real that government fa
Page 115 and 116:
REFERENCES Adam, E.E. Jr., J.C. Her
Page 117 and 118:
McKinney, Jerome B., 1995. Understa
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SYMBOLISM AND BUSINESS EDGAR J. RID
Page 121 and 122:
Once it is understood that we live
Page 123 and 124:
must be eliminated because racism n
Page 125 and 126:
which are people of color, out of t
Page 127 and 128:
The productivity problems of Americ
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