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Example text

Work steps are then balanced according to the resulting takt in an effort to meet customer demand as quickly as possible with minimum in-process and finished-goods inventories. Methods such as “jidoka” (the Japanese term for the practice of stopping the production line when a defect occurs) help limit inventory exposure to high amounts of rework and/or scrap. TPS documentation indicates that if customer demand changes, significant challenges result. As the contemporary response to TPS, mathematically based Demand Flow Technology creates a flexible flow of products, thereby removing manufacturing as a variable in meeting customer demand on a daily basis.

What Is World-Class Manufacturing? World-class manufacturing is a philosophy that unites a range of techniques to achieve significant continuous improvement in manufacturing performance. It is a process-driven approach that addresses quality, cost, delivery speed, reliability, flexibility, and customer service as functions of success. The Case for DFT A thorough understanding of Demand Flow tools and techniques quickly highlights the true power of this technology. DFT encompasses all of the effective attributes of other flow systems and methodologies, and combines the best of the various approaches and techniques used in manufacturing today.

The manufacturing scheduling process utilizes subassembly-manufacturing techniques, along with a multilevel bill of material. Because of rigid scheduling and its required lead times, this traditional manufacturing technique requires a substantial amount of inventory in process at all times. Additionally, manufacturers who employ these scheduling techniques realize 10 inventory turns or less per year, on average. The resulting increase of manufacturing lead times can complicate forecasting, given that the longer the manufacturing lead time, the more difficult it will be to predict customers’ future needs.

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