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How is Chipageddon affecting you?

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tom66:

--- Quote from: Karel on January 11, 2023, 03:08:04 pm ---Not even the factory that produces, for example, plastic parts for the cars?
Factories have parallel production lines for every part separate? How is that possible?

--- End quote ---

Well, at the volumes a car is produced at, for plastic parts it's very likely that a factory would be dedicated to making parts only for one vehicle line or manufacturer.  Each part needs a dedicated mould and some of these moulds are extremely expensive (dust-bin sized mould, but with fine details)  so there may only be a few made.

For instance, most of the plastic parts in my Golf have a 'SPAIN' manufacturing location so I guess either a VW owned factory or subcontractor.  VW sold about 500k per year of the Mk7 Golf, so if each car needs 50 x injection moulded parts (whole dashboard is injection moulded now on modern car) then it's easy to see how such a production line would be kept busy pretty much continuously.

And as long as the flow rate is there, JIT works 'fine'.  Warehousing even a day's production, especially considering the size of a dashboard or centre console part, would be quite expensive. 

An aside: One thing to note is how expensive the finishes applied to dashboard parts are, for instance, which is one reason that it's quite common to find hard, unpleasant plastics in cheaper cars.  A lot of effort is expended in finding ways to polymerise the outer skin of the part to give it a pleasant feeling, but some of these finishes have to be hand applied.  The so-called "elephants skin" effect on the cheaper models is used to hide moulding defects and thermal sink in such large parts.  The quality of plastics in cars has really come along in the last 20 years!

snarkysparky:
Jit is about *forcing*  reliability into the manufacturing process.  Lines just simply cannot go down.
This works to varying degree.  I would guess it is enforced more strictly for highly reliable processes and not really spoken about for processes that cannot be made 100 percent reliable/

peter-h:

--- Quote ---It can work in a well managed supply chain under very specific circumstances. We had a study mission to see how Lexus manage their Tier 1 and Tier 2 supply chain. It really was JIT, 15 minute delivery intervals, zero warehousing anywhere in the chain. They visit and train their suppliers not to keep inventory beyond a 4 hour buffer stock.
--- End quote ---

A friend was one of their suppliers. JIT worked while it worked. When something "broke", he had to hire a turbine helicopter at GBP 3000/hr to deliver the parts to Toyota/Lexus :) Who do you think paid for the heli?

JIT is BS.

And when it goes wrong, nobody will go public with that because a) they are under NDAs b) the customer will terminate the relationship.

bookaboo:

--- Quote from: Karel on January 11, 2023, 03:08:04 pm ---
--- Quote from: bookaboo on January 11, 2023, 02:25:14 pm ---
--- Quote ---JIT never really existed. It is a euphemism for a big company (customer) shafting a small company (supplier) into keeping stock free of charge. In electronics especially, it can't work.
--- End quote ---

It can work in a well managed supply chain under very specific circumstances. We had a study mission to see how Lexus manage their Tier 1 and Tier 2 supply chain. It really was JIT, 15 minute delivery intervals, zero warehousing anywhere in the chain. They visit and train their suppliers not to keep inventory beyond a 4 hour buffer stock. The whole thing

--- End quote ---

Not even the factory that produces, for example, plastic parts for the cars?
Factories have parallel production lines for every part separate? How is that possible?

--- End quote ---


In general, no. The Toyota Production System emphasises SMED (single minute exchange of dies, although the "single minute" shouldn't be interpreted literally), they change over the tooling to avoid batches. We saw the plastic parts for air vents go straight from the tool die, quick inspection and into a tote. The tote would have been in the main plant same day and the part would only be touched once more to fit it to the car.

bookaboo:

--- Quote from: peter-h on January 11, 2023, 04:02:34 pm ---
--- Quote ---It can work in a well managed supply chain under very specific circumstances. We had a study mission to see how Lexus manage their Tier 1 and Tier 2 supply chain. It really was JIT, 15 minute delivery intervals, zero warehousing anywhere in the chain. They visit and train their suppliers not to keep inventory beyond a 4 hour buffer stock.
--- End quote ---

A friend was one of their suppliers. JIT worked while it worked. When something "broke", he had to hire a turbine helicopter at GBP 3000/hr to deliver the parts to Toyota/Lexus :) Who do you think paid for the heli?

JIT is BS.

And when it goes wrong, nobody will go public with that because a) they are under NDAs b) the customer will terminate the relationship.

--- End quote ---

It's a very nuanced system that it took Toyota from bankruptcy to consistently the most profitable car company in the world. It's exactly those helicopter rides that make it so good, you can't hide that, you have to be so good it doesn't happen often enough to matter.

It's currently not entirely possible for SME electronics but there are a hell of a lot of lessons to be learnt from it for any business.

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