Just In Time

MEMBERS
SONAM JADIA PRIYANKA LALIT SHIKHA MEHRA JASLEEN NAKRA RUCHA PILGAONKAR

INTRODUCTION

Just-In-Time is a philosophy of manufacturing based on planned elimination of all waste and on continuous improvement of productivity. Just-In-Time is a Japanese manufacturing management method developed in 1970s & was first adopted by Toyota manufacturing plants at Taiichi Ohno. It is an approach for process improvement . It uses Timeliness as a lever to lower cost , improve quality & responsiveness.

Goals of JIT
Inc. productivity Reduce costs 0 Defect process

Waste elimination

Efficiency

Optimal cost/quality relationship

Respond to customer needs

Competi tiveness

Reliable relationship with suppliers

Just-inJust-in-Time Principles
Traditional Manufacturing Increases inventory to protect against process problems Just-inJust-in-Time Manufacturing Reduces inventory

Increases lead time to Reduces lead time protect against uncertainty Disregards setup time Reduces setup time as an improvement priority Emphasizes processoriented layout Emphasizes work of individuals, following manager instructions Emphasizes productorientedlayout Emphasizes team-oriented employee involvement

Just-inJust-in-Time Principles cntd cntd

Traditional Manufacturing Emphasizes push manufacturing Tolerates defects Treats suppliers as armslength, independent entities Just-inJust-in-Time Manufacturing Emphasizes pull manufacturing

Emphasizes zero defects Emphasizes supplier partnering

Elements of JIT

People JIT

Systems

Plant

People

Stockholders

Labor Management Govt support

System
Material Requirement Planning Manufacturing Resource Planning

computer based bottom-up manufacturing approach production plan master production schedule

Demand
Pull

Plant Layout

Kanban

Plant
Continuous improvement Reduce inventory Self inspection

Kanban
 Kanban: Kan p visual, Ban pcard/board  It is a signaling system to trigger action

Push system Demand forecast

Pull system Customer demand

Kanban cards

Information about item Its specification Preceding process Succeeding process Quantities of such items

Companies That Have Implemented JIT

JIT IN PRODUCTION SYSTEMS

There are major differences between the production systems. First, each production system is designed to produce different numbers of products in different volumes. Second, each system arranges its equipment in a different layout. The material flow is different because of that layout.

CONTD.

Third and most important, each provides different levels of output viz: Cost Quality Performance Delivery Flexibility Innovativeness Output. The JIT production system can make improvements in all the 6 outputs mentioned above.

SEVEN PROMINENT TYPES OF WASTE TO BE ELIMINATED: Waste from Overproduction Transportation Waste Processing Waste Waste from Product Defects Waste of waiting/idle time Inventory Waste Waste of Motion

IMPLEMENTATION OF JIT
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JIT is to eliminate waste in all its forms. The assumption of JIT is that we cannot sell everything we make. Thus, we must produce salable goods. Operation = Motion (Waste) + Work (Added Value) Motion alone is a waste that adds cost (counting things, moving boxes, transporting goods etc) Inventory decouples individual operations and thereby creates waste to buffer the operations against the effect of a different forms of waste. For real improvement, we must ask "why" ,when we encounter any form of waste.

IMPLEMENTATION CNTD 5SS FOR WORKPLACE IMPROVEMENT

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Proper arrangement (sort through and sort out, identify what you need, discard what you do not need ) Orderliness (assign a separate location for all essential items) Cleanliness (keep the workplace spotless at all times) Cleanup (maintain equipment and tools) Discipline (stick to the rules scrupulously)

CNTD

Place the machines in process sequence Design a cellular (U-shaped) layout Make one piece at a time in the cell Cross-train workers to handle multiple processes Produce according to the cycle time Have the operators work standing up and walking Use slower, dedicated machines that are smaller and less expensive

AWARENESS REVOLUTION

1. Abolish old tradition concepts. 2. Assume that new method will work. 3. No excuses are accepted. 4. It is not seeking for perfection, absolutely zero-defect process, few defects is acceptable. 5. Correct mistakes immediately. 6. Do not spend money on improvement. 7. Use you brain to solve problem. 8. Repeat to ask yourself 5 times before any decision. 9. Gather information from several people, more is better! 10. Remember that improvement has no limits.

FLOW MANUFACTURING
Arrange machines in sequence. U-shaped production line (Cellular Manufacturing). Produce one-piece at a time. Train workers to be multi-skilled. Follow the cycle time. Let the workers standing and walking around while working. Use small and dedicated machines.

Standard Operation
Cycle time Work sequence Standard stock-on-hand Use operation charts

Multi-process handling
Multi-process handling A worker should handle several different processes at once, this is also called "vertical handling" and this is the basis for JIT production

REQUIREMENTS FOR A PROPER JIT MANAGEMENT

STANDARDIZATION: Where the supplies are standardized and the suppliers are trustable and close to the plant. SOFTWARE:For JIT to work efficiently Supply Chain Planning software, companies have in the mean time extended Just-in-time manufacturing externally, by demanding from their suppliers to deliver inventory to the factory only when it's needed. MULTI-FUNCTIONALITY :In JIT workers & Machines are multifunctional and are required to perform different tasks. CLEANLINESS :Environment is kept clean and free of waste. SCHEDULES: Schedules are prepared only for the final assembly line. QUALITY: Quality within JIT manufacturing is necessary, because without a quality program in JIT, the JIT will fail

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