Mr. Taiichi Ohno introduced the Just-In-Time (JIT) system. [1] JIT is more than just an inventory reduction system, it is also about reducing changeover times and modernizing factories. [2] JIT means that the right parts arrive at the assembly line at the exact time they are needed and only in the necessary amounts. Kanban is the method used to convey information about production orders to ensure smooth workflow. The goal of JIT is cost reduction through the absolute elimination of waste. Takt time establishes the rate of production to match customer demand.

1. Introduced
By
Mr. Taiichi Ohno

2. JUST IN TIME(JIT)
JIT is much more than an inventory
reducing system
JIT is much more than reducing
change over time
JIT is much more than modernizing
the factory

3. Mr. Ohno says:
Making a factory operate for the company just
like human body operates for an individual.
We should have a system in a factory that
automatically responds when problem occurs.

4. JIT means that in a flow process, the right
parts needed in assembly reach the assembly
line at the right time they are needed and
only in the amount needed.
Approach:
ZERO Inventory.

5. Problem: 1.Upset in Production
2. Mistake in paperwork
3.Defective products & rework
4.Trouble with equipment
5.Absenteeism etc.
Result of Waste:
1.Huge inventory
2.Less Productivity
3.Less profitability

6. Piller of TPS
JIT- Absolute elimination of waste
Autonomation - Automation with a
human touch

7. KANBAN is the means used for
conveying information about picking up or
receiving the production order
TPS is supported by JIT system

8. KANBAN method by which the TPS
moves smoothly
Give the machine Intelligence
1. By automatic checking system
2. By prevent automatically
3. By automatic stopping device
4. By safety device
5. By fixed position stopping
6. By full work system
7. By foolproofing system

9. GOAL of JUST IN TIME
Cost Reduction

10. Focus of Japanese Industry
1.Establishing a production flow of
one machine one operator.
2.One operator many machine in
different process

11. The power of individual skill and
teamwork :
1. Implementing autonomation is up
to the managers & supervisors
2. To adopt the simple movement of
the human operator to the
autonomation machine

12. 5 Why : Complete Waste analysis
Present capacity = work + waste

13. Type of Waste
1. Over production
2. Time on hand ( waiting )
3. Transportation
4. Processing itself
5. Stock on hand ( inventory )
6. Movement
7. Making defective product

14. Philosophy
First principle – My Plant
(Owner the work area)

15. What is TAKT time ?
“TAKT” is the German word for the baton that an orchestra
conductor uses to regulate the speed, beat or timing at which
musicians play.
So Takt time is Beat time / Rate time / heart Beat.
Means the time that a complete product is finished
Exmp: If you have a Takt time of two minutes that means
every two minutes a complete product , assembly or machine
is produced off the line

16. How is TAKT time established?
The Customers buying rate establishes Takt time. It’s the rate at
which the customer buys your product. So this means that over
the course of a day , week , month or year the customer s you
sell to are buying at a rate of Takt time.
If you can’t predict when and how much a customer will buy,
then your Takt time shuold change.
Your Production staffing should be set accordingly.

17. Imbalances in Takt time
Producing to takt time with optimal staffing is where you want
to be. Where you have the right amount of people to produce
your product within your established Takt time. The operators
cycle times are loaded to Takt time.
Imbalances in Takt time, especially in older facilities, drive
security, one step on “the lean journey”is to monitor Summed
Takt time in order to move toward preventive (rather than
reactive) quality measures. That is , if you can defect , contain
and correct a problem within Takt + Buffer time(Summed
Takt) then you have taken a step toward Error Proofing. This is
no substitute for continuously improving a balanced Takt time
( thereby eliminating security inventory/buffering)but, rather ,it
is a first step which you can institute quickly and economically.

18. TAKT time Calculation :
1.Input the demand(daily, weekly, monthly etc.)
2.Determine the gross available time in a shift
3.List all the deduction and the corresponding time
4.No.of shift to calculate the total available seconds
5.Takt time is calculated as a function of available
time divided by the demand

19. Example
1.Demand (Daily/Weekly/Monthly): 100 units
2.Available time(Daily gross availability /shift) : 480 minutes
3.Deduction to shift availability
Description Time
Tea break 10 min.
Lunch 30 min.
Miscellaneous(M/H) 10min
Total 50min
4.Net availability / shift (2-3) : (480-50)*60 Sec = 25800 Seconds.
5.Prod.Requirement(Takt time) :
Total availability(25800)/Demand(100) = 258 sec/unit

20. Necessity is the mother of
invention
Automation
Skill & Talent of Individuals
Control Overproduction
Prevent Defect free Product
Visual Control( Management By Sight)