A presentation

by:

Just

In

Time manufacturing

TALIB KHAN VIVEK GAUR

MBA ALIGARH MUSLIM UNIVERSITY

MALAPPURAM CENTRE

content Introduction Just-in-time manufacturing

philosophy Elements of just in time

manufacturing Benefits of Jit manufacturing Manufacturing JIT implementation conclusion

INTRODUCTION What is just-in-time manufacturing Jit is philosophy of manufacturing based on

planned elimination of all waste and continuous improvement of productivity it encompasses the successful execution of all manufacturing activities required to produce a final product from design engineering to delivery and including all the states of conversion from raw material onward.

Just-In-Time PhilosophyThe philosophy of JIT can be traced back to Henry Ford,

but formalized JIT originated in Japan as the Toyota Production System. W. Edwards Deming’s lesson of variability reduction was a huge influence.

The focus of JIT is to improve the system of production by eliminating

all forms of WASTE.

JIT is a long-term approach to process improvement. It uses timeliness as a lever to lower costs, improve quality and improve responsiveness. However, JIT requires enormous commitment. It took Toyota more than 25 years to get right!

ELEMENTS OF JIT

Eliminating wastes Total quality management Parallel processing Jit purchasing E-commerce and JIT purchasing Reducing inventories through setup

reduction working towards repetitive

manufacturing

JIT versus a traditional OM philosophyTraditional Goal: maximize production by minimizing disruptions Management Assumption: we can sell what we

make

JIT Goal: Produce salable goods as quickly and efficiently

as possible Management Assumption: we make what we can

sell

Reduces inventory

Reduces lead time

Reduces setup time

Just-in-Time ManufacturingTraditional Manufacturing

Increases inventory to protect against process problems

Increases lead time to protect against uncertainty

Disregards setup timeas an improvement priority

Just-in-Time Principles

Emphasizes team-oriented employee involvement

Emphasizes pull manufacturing

Emphasizes zero defects

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Just-in-Time ManufacturingTraditional Manufacturing

Emphasizes work of individuals, following manager instructions

Emphasizes push manufacturing

Tolerates defects

Some change are needed Stabilize production schedule Increase production capacity of

manufacturing Improve the product quality Cross train worker Reduce equipment breakdowns

through preventive maintenance Develop long term relationship that

avoid interruption to the material flows

2/22/2009just in time by ravindra9

Benefits of JITThe main benefits of JIT are listed below. Set up times are significantly reduced in the factory. Cutting down the set up time

to be more productive will allow the company to improve their bottom line to look more efficient and focus time spent on other areas that may need improvement.

The flows of goods from warehouse to shelves are improved. Having employees focused on specific areas of the system will allow them to process goods faster instead of having them vulnerable to fatigue from doing too many jobs at once and simplifies the tasks at hand. Small or individual piece lot sizes reduce lot delay inventories which simplifies inventory flow and its management.

Employees who possess multiple skills are utilized more efficiently. Having employees trained to work on different parts of the inventory cycle system will allow companies to use workers in situations where they are needed when there is a shortage of workers and a high demand for a particular product.

Contd. Better consistency of scheduling and consistency of employee work hours. If

there is no demand for a product at the time, workers don’t have to be working. This can save the company money by not having to pay workers for a job not completed or could have them focus on other jobs around the warehouse that would not necessarily be done on a normal day.

Increased emphasis on supplier relationships. No company wants a break in their inventory system that would create a shortage of supplies while not having inventory sit on shelves. Having a trusting supplier relationship means that you can rely on goods being there when you need them in order to satisfy the company and keep the company name in good standing with the public.

Supplies continue around the clock keeping workers productive and businesses focused on turnover. Having management focused on meeting deadlines will make employees work hard to meet the company goals to see benefits in terms of job satisfaction, promotion or even higher pay.

The Implementation of JIT

The goal of 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 (low cost, high quality, etc...) quickly.

Operation = Motion (Waste) + Work (Added Value) Motion alone is a waste that adds cost (counting things, moving boxes,

transporting goods, preparation time, waiting, producing defects, over production, handling materials, switching things on)

Inventory decouples individual operations and thereby creates waste (non-value-added motion) to buffer the operations against the effect of a different form of waste (long setups, poor material handling procedures, production of defects, etc.)

For real improvement, we must ask "why" when we encounter any form of waste.

Step 1: Awareness

The implementation of JIT

Seiri: Proper arrangement (sort through and sort out, identify what you need, discard what you do not need )

Seiton: Orderliness (assign a separate location for all essential items) Seiso: Cleanliness (keep the workplace spotless at all times) Seiketsu: Cleanup (maintain equipment and tools) Shitsuke: Discipline (stick to the rules scrupulously)

Step 2: Workplace Improvement (the 5 S’s)

The implementation of JIT

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

Step 3: Flow Manufacturing (one piece at a time)

Thank you Any queries???