JUST-IN-TIMEMANUFACTURING

A PowerPoint Presentation

BYSWATI(54),

MEENAL(39),REENU(45),

JAYA(66)

WHAT IS JIT?

• JIT is a manufacturing philosophy involving an integrated set of procedures/activities designed to achieve a volume of production using minimal inventories.

• A highly coordinated processing system in which goods move through the system, and services are performed, just as they need.

HOW IT WORKS?

HISTORY

• Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry.

• Founded by Taiichi Ohno, a vice president of Toyota.• Basically implemented in Toyota plant 1950, well

established after 1970.

FOLLOWERS

• Adopted by General Electrical in the USA in the 1980.• Some companies referred JIT with different names:i. TOYOTA – ‘Toyota System’ii. IBM – ‘Continuous flow manufacturing’iii. GE- ‘Management by sight’iv. HEWLETT- PACKARD- ‘stockless production & repetitive

manufacturing system’

7 WASTES

1) Waste of over production2) Waste of waiting3) Waste of transportation4) Waste of Underutilization

of Employees5) Waste of Inventory6) Waste of motion7) Waste of making defective

products

PRINCIPLES OF JIT PRODUCTION

TOTAL QUALITY MANAGEMENT

• Seek long-term commitment

• Quality must be a higher priority than cost

• Minimize Waste

PRODUCTION MANAGEMENT

• Pull System vs. Push System– Pull = Made to order– Push = Made for inventory

• Communication Techniques– Completion of task-Kanban – Problem- Andon or siren/light

• Flexibility of the system

• Design For Testability – Poka-Yoke= Mistake-proofing

SUPPLIER MANAGEMENT

• Establish Long Term Relationships with few suppliers.

• Delivery of Parts = 100% Defect Free– Where they are needed– When they are needed– The exact quantity

• Work Together

• Elimination of inspection of parts

E.g. Toyota Productions

Material quality problems

Long setups

Poor training Break

downs

Material handling

Traditional systems use inventory (water) to buffer the process from problems (rocks) that cause disruption.

Water = Inventory

INVENTORY MANAGEMENT Eliminate Safety Stock = Zero Inventory Inventory is Evil

Material quality problems

Long setups

Poor training

Break downs

Material handling

JIT systems view inventory as waste and work to lower inventory levels to expose and correct the problems (rocks)

that cause disruption.

Material quality problems

Long setups

Poor training

Break downsMaterial handling

Lowering the level of inventory is relatively easy to do. However, the problems that arise must be corrected

quickly … Otherwise, the process will flounder.

HUMAN RESOURCE MANAGEMENT

• Company-wide Involvement– Motivation for

continuous improvement

– Problem Solving

• Diversified Employees

• Management Support and Empowerment of workforce

JIT MANUFACTURING BUILDING BLOCKS

• Product • Design

• Process• Design

• Personnel• Elements

• Manufactur-ing Planning

• Eliminate disruptions• Make the system flexible

• Reduce setup• and lead times

• Eliminate waste• Minimize inventories

• A• balanced• rapid flow

• Ultimate• Goal

• Supporting• Goals

REQUIREMENTS OF JIT• Respond to Customer

Requirements• Integrate all Processes• Employee Participation• Company wide

Commitment to education• Eliminate redundancy• Reduce all Inventory• Establish Continuous

Improvement Goals

• Use a pull Production System

• Design products for Manufacturing

• Develop Controllable Production Processes

• Have Defect Prevention Program

• Reduce Setup Times• Build Products to

Specification

OBSTACLES IN CONVERSION

• Management not committed• Workers not cooperative• Decide which parts need most effort• Start by trying to reduce setup times• Gradually convert operations• Convert suppliers to JIT• Prepare for obstacles• Suppliers may

resist

ADVANTAGES OF JIT

• High quality

• Flexibility

• Reduced setup times

• Reduced need for indirect labor

• Less waste

• Low warehouse cost

• Synchronization between production scheduling and work hour

DISADVANTAGES OF JIT

• Time consuming

• No spare product to meet un expected order

• Supply Shock : If products do not reach on time

• High risk factor

JIT IN GOODS :

• Leveraged JIT principles to make its manufacturing process a success

• Leverage their suppliers to achieve the JIT goal

• Provide exceptionally short set up times to their customers

• Suppliers carry inventory instead of carrying it themselves.

• Has dependable suppliers with the ability to meet its demanding lead time requirements.

• Seamless system that allows it to transmit its component on requirements

• Willingness of suppliers to keep inventory on hand.

JIT IN SERVICES: MAC D

McDonald’s is the best example of JIT in Services !

• McDonald's doesn't begin to cook until a customer has placed a specific order.

• The major benefits are better food at a lower cost.

• Wastage is reduced along with an improvised taste that makes you want to scream out I’m Lovin’ It !

THANK YOU!!