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Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
Pulljit Sample
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Pulljit Sample


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  • 1. Pull Manufacturing and Just In Time Superfactory Manufacturing Excellence Series Lean Overview 5S & Visual Factory Cellular Manufacturing Jidoka Kaizen Poka Yoke & Mistake Proofing Quick Changeover & SMED Production Preparation Process (3P) Pull Manufacturing & Just In Time Standard Work Theory of Constraints Total Productive Maintenance Training Within Industry (TWI) Value Streams
  • 2. Contents © 2007 Superfactory™. All Rights Reserved.
    • Introduction
    • Background and History
    • Components and Implementation
    • Knowledge Check
  • 3. Introduction © 2007 Superfactory™. All Rights Reserved.
    • Just In Time ( JIT ) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and cycle time. The process is driven by a series of signals, or Kanban, that tell production processes to make the next part. When implemented correctly, JIT can lead to dramatic improvements in a manufacturing organization's return on investment, quality, and efficiency.
  • 4. Components and Implementation © 2007 Superfactory™. All Rights Reserved.
    • Pull vs. Push Scheduling
    • The Problem of Inventory
    • Just In Time
      • Principles
      • Benefits and Limitations
    • Implementing JIT
      • Kanban
      • Pull Systems
      • Quality
      • One Piece Flow
      • Continuous Flow
      • Takt Time
    • JIT and Suppliers
  • 5. Push Vs. Pull Scheduling © 2007 Superfactory™. All Rights Reserved.
    • Push Scheduling
      • traditional approach
      • “ move the job on when finished”
      • problems - creates excessive inventory
    • Pull scheduling
      • coordinated production
      • driven by demand (pulled through system)
      • extensive use of visual triggers
      • (production/withdrawal kanbans)
  • 6. Inventory Hides Problems © 2007 Superfactory™. All Rights Reserved. Scrap Work in process inventory level (hides problems) Unreliable Vendors Capacity Imbalances
  • 7. The Philosophy of JIT © 2007 Superfactory™. All Rights Reserved.
    • JIT means getting the right quantity of goods at the right place and the right time
    • Often termed “Lean Systems”
    • All waste must be eliminated- non value items
    • Broad view that entire organization must focus on serving customers
    • JIT is built on simplicity- the simpler the better
    • Focuses on improving every operation- Kaizen
    • Install simple visible control systems
    • Flexibility to produce different models/features
  • 8. Elements of JIT Manufacturing © 2007 Superfactory™. All Rights Reserved.
    • JIT Manufacturing is a philosophy of value-added manufacturing
    • Achieved by
      • Inventory reduction - exposes problems
      • Kanbans & pull production systems
      • Small lots & quick setups
      • Uniform plant loading
      • Flexible resources
      • Efficient facility layouts
  • 9. JIT Tactics © 2007 Superfactory™. All Rights Reserved.
    • Single Minute Exchange of Dies (SMED)
    • Statistical Process Control
    • Use of standard containers
    • Doable stable schedules with adequate visibility
    • TAKT-Time
    • 5-S Program
    • Kaizen Event
    • Visual control
    • Flexible workers
    • Tools at the point of need
    • Product redesign
    • Group Technology
    • Total Productive Maintenance
  • 10. JIT and Suppliers © 2007 Superfactory™. All Rights Reserved.
    • Few
    • Nearby (if possible)
    • Repeat business/Longer Term Agreements
    • Analysis to enable desirable suppliers to become or stay price competitive
    • JIT Logistics:
      • Frequent Deliveries/Smaller Quantities
      • Exact Quantities
      • Consumption initiates deliveries
      • Deliveries directly to the point of use
    • Perfect Parts
    • Concurrent engineering design practices