Accessible to the Lean novice and shop floor employee, The Basics of Line Balancing and JIT Kitting explores line balancing and the pre-assembly of components into a finished product in a just-in-time fashion (JIT Kitting). It explains how to use time studies, develop yamazumi charts, discover and eliminate waste, balance your line, and create new standard work content for the shop floor.
The book facilitates a clear understanding of the seven deadly wastes (muda) as well as what you can do to eliminate them from your facility. Describing the purpose and use of standard work, it explains how to properly staff work cells and how to develop flex plans for fluctuations in demand using this data. The first few chapters explain how to determine takt time and how to use that information along with time studies to identify when you are not meeting customer demand.
The chapters on JIT Kitting explain how there are other advantages to kitting besides eliminating waste and increasing productivity. The book explains how you can use JIT Kitting to improve quality by having the parts available and limiting the options of numerous parts to the operator. It also provides the understanding needed to ensure the right parts are installed, thereby correcting issues with the build of materials.
Table of Contents
Where Are My Hidden Costs?
Understanding Your Rhythm
"When in Doubt, Throw It Out."
"A Place for Everything and Everything in Its Place."
"Keep It Clean."
"This Is What Is Expected Every Day in Every Area."
"Audit the Process to Ensure Sustainability."
Line Balance and Yamazumi
Variable Work Content
Rebalance Removing the Waste
What Type of Kit?
What Type of Transportation?
Designed for Kits, Tools, and Ergonomics
Layout for Station and Tugger Delivery
Size and Layout of the Supermarket
Pick Lists and Heijunka
Material Handling Takt Times
Material Handling Is Now on a Takt Time
Refining the Process
Correcting Mistakes and Anticipating the Crash Period
High Mix and Complexity
Beverly Townsend is a Lean manufacturing manager and artist from Kentucky. She is an expert in Lean, with years of experience starting at Toyota. She also holds chairman and president’s awards for her Lean achievements in operation excellence for JIT kitting and waste elimination. Her experience involves teaching and mentoring in Lean as well as implementation. Her efforts have transformed facilities into benchmark plants, as well as sustained business and growth.