Just-In-Time Systems
Submitted toMs. Neha Gulati
Submitted byTanvi Verma
A Brief Overview
Meaning of JIT Manufacturing History of JIT Introduction phase Core Logic Process Central Themes of JIT Prerequisites for JIT Implementation Major Misconceptions of JIT
A Brief Overview (contd.)
Requirements of JIT Example Kinds of JIT Systems
Just-In-Time Manufacturing:
The principle of Just in time (JIT) is to eliminate sources of manufacturing waste by getting right quantity of raw materials and producing the right quantity of products in the right place at the right time.
History of JIT
Just-In-Time is a Japanese manufacturing management method developed in 1970s. It was first adopted by Toyota manufacturing plants by Taiichi Ohno. The main concern at that time was to meet consumer demands. Because of the success of JIT management, Taiichi Ohno was named the Father of JIT.
History (cont.)
After the first introduction of JIT by Toyota, many companies followed up and around mid 1970s, it gained extended support and widely used by many companies. After second World War , Japanese worked on "optimal cost/quality relationship.
There were many deep rooted defects. Lastly, the existing system did not manage well , so, there was a need to have a faster and reliable delivery system in order to handle customers needs. Thus, JIT manufacturing management was developed based on this problems.
Introduction Phase
BUILDING AWARENESS AMONG EMPLOYEES 5S FOR FACTORY IMPROVEMENT FLOW MANUFACTURING
STANDARDISED OPERATIONS
LEVELLING
BUILDING AWARENESS AMONG EMPLOYEES
It means giving up old concept of managing and adopting JIT way of thinking. It adopted many principles:
1. Abolish old tradition concepts. 2. Assume that new method will work. 3. It is not seeking for perfection, absolutely zerodefect process, few defects is acceptable. [Link] mistakes immediately. 5. Do not spend money on improvement.
OLD CONCEPT- "Unneeded goods-In unneeded quantities-At unneeded times" JIT- "Needed goods-In needed quantities-At needed times" The main point here is to have an awareness of the need of throwing out old system and adopting a new one.
5S FOR FACTORY IMPROVEMENT
The 5Ss stand for: Seiri - Proper Arrangement Seiton - Orderliness Seiso - Cleanliness Seiketsu - Cleanup Shitsuke - Discipline
Seiri - Proper Arrangement means sorting what you have, identifying the needs and throwing out those unnecessary. Seiton - Orderliness means making thing in order. Examples include keeping shelves in order, keeping storage areas in order, keeping workplace in order, keeping worktables in order and keeping the office in order.
Seiso - Cleanliness means having a clean workplace, equipment, etc. Seiketsu - Cleanup mean maintaining equipment and tools. Shitsuke - Discipline means following the rules and making them a habit.
FLOW MANUFACTURING
Flow manufacturing means producing one single piece of product at a time but multi-handling which follows the process sequence. There are several main points concerning flow manufacturing:
1. Arrange machines in sequence. 2. Produce one-piece at a time. 3. Train workers to be multi-skilled. 4. Follow the cycle time.
LEVELLING
Levelling of production is done by using better scheduling and planning techniques.
STANDARD OPERATINOS
Standard Operation means to produce quality safely and less expensively through efficient rules and methods of arranging people, products and machines. 1. Cycle time- It means how long it would take to "carry out part all the way through the cell".
Calculation of cycle time Daily Quantity Required = Monthly Quantity Needed / Working Days per month Cycle Time = Working Hours per day / Daily Quantity Required
2. Work sequence [Link] stock-on-hand 4. Use operation charts
Core Logic
The core logic of JIT is one of the elimination of waste in a manufacturing system using a DELIBRATE method. There are many constraints in a manufacturing system like: Poor Quality Defective Material
Variable Processing Times Bottleneck Lack of Training Inadequate Information Machine Breakdown Unrealistic Schedules
Then review will be done by the managers, which may call for adding more to safety stock to restore production levels back to normal rates. But the philosophy of JIT is to deliberately create some disturbances in the system to uncover the problem areas.
Process
[Link] withdrawal of buffer inventories [Link] buffer inventories [Link] awareness of problems and causes
LOT SIZE REDUCTION JIT PRODUCTION QUALITY CONTROL
5. Smoother output rates. 6. Review of steps.
Central Themes Surrounding Just-In-Time
Simplicity
Quality
Elimination of Waste
Prerequisites for JIT Implementation
A Reason for Changing Executive Commitment Strategic Manufacturing Plan Commitment to Action
Requirements for JIT
Respond o Customer Requirements Integrate all Processes in the Manufacturing System Employee Participation in Meeting Commitments Company wide Commitment to education Eliminate redundancy Reduce all Inventory Establish Continuous Improvement Goals
Requirements for
JIT(contd)
Design products for Manufacturing Develop Controllable Production Processes
Have a Defect Prevention Program Reduce Setup Times Build Products to Specification
A Real World Example
The Toyota Production System
KINDS OF JIT SYSTEMS
JIT MANUFACTURING JIT PURCHASING JIT PRODUCTION SYSTEM
JIT PURCHASING
Just-in-Time (JIT) Purchasing is the purchase of materials or goods so they are delivered just as needed for production or sales JIT is popular because carrying costs are actually much greater than estimated because warehousing, handing, shrinkage and investment costs have not been correctly estimated
JIT reduces the cost of placing a purchase order because: Long-term purchasing agreements define price and quality terms. Individual purchase orders covered by those agreements require no additional negotiation regarding price or quality Companies are using electronic links to place purchase orders at a small fraction of traditional methods (phone or mail) Companies are using purchase-order cards
Relevant Costs in JIT Purchasing
Purchasing Costs Stock out Costs Quality Costs
JIT Production System
JIT (Lean) Production is a demand-pull manufacturing system that manufactures each component in a production line as soon as and only when needed by the next step in the production line Demand triggers each step of the production process, starting with customer demand for a finished product and working backward Demand pulls an order through the production line
JIT Production Goals
1. Meet customer demand in a timely basis, 2. with high-quality products, 3. at the lowest possible cost.
Benefits of JIT Production
Lower overhead costs Lower inventory levels Heightened emphasis on improving quality by eliminating the specific causes of rework, scrap, and waste Lower manufacturing lead times
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