Just

TimeIn

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

Waste elimination

Respond tocustomer needs

Competitiveness

Reliable relationshipwith suppliers

Efficiency Optimal cost/qualityrelationship

Inc.productivity

Reduce costs

0 Defectprocess

Just-in-Time Principles

Increases inventory to protect against process problems

Reduces inventory

Increases lead time to protect against uncertainty

Reduces lead time

Disregards setup timeas an improvement priority

Reduces setup time

Emphasizes process-oriented layout

Emphasizes product-orientedlayout

Emphasizes work of individuals, following manager instructions

Emphasizes team-oriented employee involvement

Traditional Manufacturing Just-in-Time Manufacturing

Emphasizes push manufacturing

Emphasizes pull manufacturing

Tolerates defects Emphasizes zero defects

Treats suppliers as “arms-length,” independent entities

Emphasizes supplier partnering

Just-in-Time Principles cntd…

Traditional Manufacturing Just-in-Time Manufacturing

Elements of JIT

People Systems

Plant

JIT

People

Stockholders

Management

Labor

Govt support

System

MaterialRequirement Planning

ManufacturingResource Planning

computer basedbottom-up

manufacturing approachproduction plan

master production schedule

Plant Layout

DemandPull

Kanban

Continuousimprovement

Reduceinventory

Selfinspection

Plant

Kanban Kanban: Kan visual, Ban card/board It is a signaling system to trigger

action

Demand forecast

Customer demand

Push system

Pull system

Kanban cards

Information about itemIts specificationPreceding processSucceeding processQuantities 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 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…

5S’S FOR WORKPLACE IMPROVEMENT

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 timeWork sequenceStandard stock-on-handUse 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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