PERSYS Reviewer
PERSYS Reviewer
Cost Savings
JIT/Lean Production System
Add: Incremental Contribution Margin
- Demand-pull manufacturing system; each Increase in Selling Price x No. of Units
component is produced as soon as and only Decrease in Var Cost x No. of Units
when needed Total
- Activity is prompted by the need of a station’s Less: Additional Costs in implementing JIT
output by another station = demand triggers an Net Benefit
order of steps
- Close coordination between stations PERFORMANCE MEASURES FOR JIT
- GOAL: 1. Financial
- Meet customer demand timely a. Inventory Turnover Ratio - inc
- High-quality products 2. NonFinancial
- Lowest cost a. Manufacturing Lead Time - dec
b. Units Produced/hour - inc
FEATURES c. No. of days of inv on hand - dec
(1.) Limited No. of Supplier d. Total Mach Set-up time/ total
- Rely on few ULTRAreliable suppliers, willing to Manufacturing time - dec
make frequent deliveries in small lots. e. No. of units to be reworked or scrap/
- DEPENDABILITY total units started and completed - dec
3. Shift products that do not have to be made to
EFFECT ON COSTING SYSTEM the bottlenecks to non-bottlenecks
- Reduce overhead costs (mat handling, 4. Reduce setup time and processing time at
warehousing, inspecting) bottleneck operations
- Direct tracing of indirect costs 5. Improve the quality of parts or products
manufactured at the bottleneck operation
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*ABC System - long run; TOC System - short run
PROCESS REENGINEERING
Reengineering PRO-FORMA FOR TOC
- rethinking and redesigning business processes
(1) COMPARE THROUGHPUT (TP) CM
- Changes roles and responsibilities
- Eliminate unnecessary activities Current TPCM
- Use IT Less: Modified TPCM
- Develop employee skills Total
MANAGING BOTTLENECKS
- keep bottlenecks busy and increase bottleneck
efficiency and capacity
1. Eliminate Idle time
2. Process only those parts that increase
throughput contribution, not those that will
remain in FG or spare parts inventory