Just-In-Time Manufacturing

David ComitaArielle HeroldJaslyn Moore

Shanelle Williamson

IntroductionJust-In-Time or JIT Manufacturing is a

management philosophy that improves businesses by decreasing inventory and the costs associated

with it. JIT focuses on constant improvement of manufacturing’s

organizations return on investment, quality and efficiency.

OutlineO History

O PhilosophyO JITs approach to Manufacturing

O Strengths O Weaknesses

O Real Life Examples

History O JIT was first developed within Toyota

manufacturing plants by Taiichi Ohno during the early 1970s.

O “The oil embargo probably triggered his theory, the program was intended to avoid wastes, reduce inventories and increase production efficiency in order to maintain Toyota’s competitive edge” (Lorefice).

HistoryO “JIT is a Japanese management philosophy which

has be applied in practice since the early 1970s in many Japanese manufacturing organizations. It was first developed and perfected within the Toyota manufacturing plants by Taiichi Ohno as a means of meeting consumer demands with minimum delays.

O “Toyota realized that JIT would only be successful if every individual within the organization was involved and committed to it, if the plant and processes were arranged for maximum output and efficiency, and if quality and production programs were scheduled to meet demands exactly” (JIT Just-in-Time manufacturing).

Philosophy O A management philosophy that

continuously focuses on integrating and streamlining the manufacturing system into the simplest process possible.

O A devotion to the process of continuously striving to minimize elements in manufacturing system that restrain productivity.

JITs approach toManufacturing's

Goal#1 :Design for optimum quality and cost and ease of manufacturing

O Design for customer satisfactionO Reduce the cost of manufacturing.O Design products for manufacturability

O Use only proven technology.O Use design standardizationO Simplify product designO Design for ease of construction and

assemblyO Minimized design and production costO Design for product strength

Application of Goal #1

O Monitor customers request and problemsO Use production and supplier involvement

in the design processO Have a formal design acceptance based

on production goalsO Set formal goals on production

performanceO Minimize the cost of labor, materials and

equipment in production

Goal#2:Minimized the resources expanded to produce a product

O Integrate and optimize every step in manufacturing process

O Build product to specificationO Use work cell and pull production

processO Locate and remove source of excess

inventoryO Set manufacturing standards at zero

defects O Have each function be responsive for

its own quality

Application of Goal#2

O Eliminate idleness in production system

O Establish goals requiring continuous improvement in the manufacturing system

O Remove all forms of gate inspection from the production system

O Establish production responsibility for product quality

Goal#3:Be responsive to the customerO Provided customer with he or she

wantsO Develop manufacturing flexibility

O Design product to meet costumer requirements

O Reduce manufacturing lead timeO Provide product on scheduleO Provide product at the expected quality

level

Application of Goal #3O Continually monitor customer satisfactionO Have engineers meet with customersO Use kanban system for triggering production

requirementsO Eliminate all unnecessary inventoryO Reduce or eliminate lead time from: supplies,

overhead processes and manufacturing functionsO Use flexible production processes and equipmentO Train employees to operate a wide variety of

process

Goal#4:Develop and trust open relationship with both suppliers and customers

O Gain supplier and customer confidence in the company’s ability to maintain commitmentsO Develop processes and procedure

necessary to commitments.O Use open kimono policy to develop

supplier and costumer confidenceO Use long-term contracts

Application to Goal#4

O Stabilize the supplier baseO Fail-safe the production processO Give employees the authority to stop

the production process (if needed)O Set a company wide policy of doing

the job rightO Deliver quality product on schedule.

Goal#5: Develop the commitment with each function and employee to improve the total manufacturing

system

O Do each job right every timeO Use an open approach to planning

and implementing a JIT systemO Focus on prevention of problems rather

than the resolution of problem after they occur

O Continuously educate employees with regard to the need of supplier, costumers and the production process

Application of Goal#5

O Design production systems with intent to prevent problems

O Establish a company wide defect prevention

O ProgramO Use total quality control and

statistical process control techniques.

WeaknessO Requires considerable discipline on the

part of every worker and supervisor; e.g. O Don’t work if no KanbanO Don’t lose Kanbans

O Requires “pushing” for long lead-time raw materials and components (or huge inventories)

O “Entropy”; i.e., explosion of WIP and Finished Goods for Products with Lots of Variety

StrengthsO Shop floor makes and implements

decision’s in response to the “Pull” on the system

O Status of shop floor easy for management to see

O Designed to respond quickly to:O Past eventsO Future events (if carefully planned

in advance by management)

Real life Example

Real Life Example

Real Life Example

Real Life Example