BE.

Mechanical Engineering

JUST IN TIME (JIT)

MECHANICAL ENGINEERING

JIT Manufacturing 1. JIT is a production methodology which aims to improve overall productivity through the elimination of waste and which leads to improved quality. 2. JIT provides for the cost efficient production in an organization and delivery of only the necessary parts in the right quantity at the right time and place while using the minimum of facilities. 3. JIT is a manufacturing system whose goals are to optimiz e process and procedure by continuously pursuing waste reduction. 4. JIT enables one to conceive design, implement and operate a manufacturing and supporting system, as an integrated whole based on the principles of continuous improvements and elimination of all kinds of wastes.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

JIT philosophy 1. The roots of the JIT system can probably be traced to the Japanese environment. 2. Japan has inherent limitation of lack of space and lack of natural resources. 3. Japanese have developed an aversi on towards all kind of wastes . 4. They view scrap and rework as waste and results in locking up of valuable materials and capital. 5. Anything that does not contribute value to the product is viewed as the waste. Thus it is quite natural for the JIT philosophy t o develop in Japan. 6. Apart from eliminating wastes JIT has another important feature utilizing the full capability of the workers. 7. Workers in JIT system are charged with responsibility for producing quality parts just in time to support the next production process. 8. The objective of JIT system is to improve the profit and return on the investment through cost reduction, inventory reduction and quality improvements. 9. Involvement of workers and elimination of waste are means of achieving the objectives. 10. So JIT manufacturing is a broad philosophy of continuous improvement that includes from mutually supportive components such as a. People participant and involvements. b. Total quality control c. Just in time flow.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

Basic Elements of JIT /Key Features

The basic elements of the JIT are

1. Flow Layout: The physical layout of production facilitates are arranged, so that the process flow is streamlined i.e. for each component, the proportion of value added time should be more, there should be minimum queuing and non value added times.

2. Smooth built up rate The buildup rate should be smooth over a monthly cycle. To achieve this, under capacity, scheduling is resorted to so that they can respond to demand changes.

3. Mixed model scheduling JIT objective is to match the production rate to demand as closely possible. One way of doing this is, to increase the flexibility of production lines, to allow concurrent assembly of different models on the same line.

4. Buffer stock removal Constant elimination of buffer stock is emp hasized, to highlight production problem scheduled by high inventory level.

5. Quality The achievement of high quality levels is prerequisite of successful JIT. Zero defects, Statistical process quality, process data collection and worker centered quality are commonly used quality programmers.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

6. Product and process simplification This is achieved through a. Rationalization of product range. b. Simplification of methods of manufacture. c. Simplification through the component item standardization.

7. Standard containers JIT emphasize small standard containers. This simplifies the material movement and use of material handling equipment.

8. Preventive maintenance JIT requires removal of cause of uncertainty and waste. Breakdown is a major cause of the uncertainty. Rigorous preventive maintenance attempts to remove the uncertainty.

9. Flexible work force Flexible work force is critical requirement of JIT. Flexible workforce is developed thorough cross functional training. It is necessary to match production rate and demand r ate closely as possible.

10. Organization in modules or cells Many JIT factories are organized in small autonomous modules or cells, each cell being totally responsible for its own production and supply of adjacent module. The cells are designed so that m aterial flow between cycles is minimized.

11. Continuous improvement JIT is not one time effort. It is a philosophy of continuous improvement .it seeks the involvement of everyone in the continuous improvements.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

Benefits of JIT The most significant benefit of JIT is to improve the responsiveness of the form to the changes in the marketplace thus providing an advantage in competition. The benefits are

1. Production Cost: Production Cost is greatly reduced due to reduction of manufacturing cycle time. Reduction of waste, inventories and elimination of non value added operations.

2. Quality: Quality is improved because of continuous quality improvements

programmes.

3. Design: Due to fast response to engineering change, alternative design can be quickly brought on the shop floor.

4. Productive improvement: It is done by reducing production lead times by moving work stations closer together, applying group technology and cellular manufacturing concept.

5. Higher productive system flexibility: Workers are trained to operate several machines, to perform maintenance task and to perform quality inspection also.

6. Administrative ease and simplicity Through the JIT, performance is improved on a regular and continuous basic gaining the competitive edges. Thus administr ation becomes very easy and simple.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

SEVEN WASTES To achieve the targets of continuous improvement in production procures following seven works are identified. By attending to these wastes, the improvement is achieved.

1. Waste of overproduction : Eliminate by reducing set up time, synchronizing quantities and timing between processes, layout problems. Make only what is needed now.

2. Waste of waiting Eliminate the bottle necks and balance uneven loads by flexible workforce and equipments.

3. Waste of transportation Establish layouts and locations, to minimize transportation and handling, if not possible to eliminate.

4. Waste of processing itself Question regarding the reason for existence of product and then why it what necessary

5. Waste of stocks Reducing all other wasters reduces stocks.

6. Waste of motion Study motion for economy and consistency. Economy improves productivity and consistency improves quality. First improve the machine, then mechanize or automate. Otherwise, there is a danger of automating the wa ste.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

7. Waste of making defective products: Develop the production process to be preventing defect from being produced, so as to eliminate inspection. At each process do not accept defects and make no defects. Make the process fail date. A quantity process always yields quality product.

JUST IN TIME (JIT)

Vaibhav V Naik

MECHANICAL ENGINEERING

JIT corner stones and Linkages to MPC

Figure provides the holistic view of JIT and the linkages to material planning and control (MPC). The model depicts JIT as having three cornerstone s: 1. Product deign 2. Manufacturing Process design 3. The whole percent concept. These all interact with the MPC system.

Figure: Cornerstones of JIT Critical activities in product design includes quality, designing for manufacture in entering cells and inducing the nuance of real level in the bill of material to all few as profile. At related manufacturing process objective has to do with efficiency. Efficiency in the cells needs to be defined in material terms not in the more common currencies of labor and capital utilization.
JUST IN TIME (JIT) Vaibhav V Naik

MECHANICAL ENGINEERING

The whole person concept will continually apply training, study, process improvements and whatever else is needed for the elimination of recurring problem. The objective is continual learning and improvements.

JUST IN TIME (JIT)

Vaibhav V Naik