Just to-time (jit)

1. JUST-IN-TIME (JIT)
Prashant Uttarkar
It is a philosophy as well as a technique that guides a manufacturing company
in organizing and managing its business more effectively, and in planning and
controlling its operations more efficiently. It create a fast and flexible process
of production as a result of which the customer would obtain desired, high-
quality and reasonably-priced. Just-in-time system are known by many
different names, including zero inventory synchronous manufacturing, lean
production, stock less production (Hewlett- Packard), material as needed
(Harley - Davidson), and continuous flow manufacturing (IBM).
JIT originated in Japan. It is a Japanese management philosophy which has
been applied in practice since the early 1970s in many Japanese manufacturing
organisations. It was first developed and perfected within the Toyota
manufacturing plants known as the "Toyota Production System" by Taiichi
Ohno as a means of meeting consumer demands with minimum delays.
 Objectives: JIT is to change the manufacturing system gradually rather
than drastically.
 Define: JIT “is getting your materials delivered just when you need
them.”
 Purpose: JIT “is inventory is to reduce inventory costs, decrease waste,
and increase efficiency.” other factor i.e Lead Time Reduction, Efficient
Manufacturing Layout, Improve Customer Satisfaction, Employee
Involvement and Morale, Quality Improvements.
 Aims: JIT is a manufacturing philosophy that aims to eliminate waste
and commitment to the customer to get product/ service in time.
 Principles: One of the important principles of JIT is mutual trust and
team work.
 Concept: The Just-In-Time (JIT) concept is a manufacturing workflow
methodology aimed at reducing flow times and costs within production
systems and the distribution of materials.
JIT Goals, is balanced, smooth and rapid flow of materials through the system:
by -
 Eliminating labour intensive non-computerized process, saving
time.
 Eliminating scope for mistakes all wasted time, effort and
resources.
 Eliminating scope of errors and contributing to quality assurance.
 Identification and planning of the materials required for the
product and each process.
 Attainment of greater shop floor control.
JIT is the concept of management that invented specially to avoid waste.
Waste" is taken in its most general sense and includes time and resources as
well as materials. Shigeo Shingo identifies Seven Deadly Wastes.
1. Overproduction
2. Waiting
3. Transportation
4. Unneeded Production
5. WIP Inventories
6. Motion & Effort
7. Defective product.
The elimination of these wastes is at the heart of the rationale for just-in-time:
eliminate these wastes, and produce better products at lower cost. Multi-item
scales have been constructed to measure key components of JIT.
1. Equipment Layout: Use of manufacturing cells, elimination of
forklifts and long conveyers, and use of smaller equipment
designed for flexible floor layout, all associated with JIT.
2. JIT Delivery by Suppliers: Whether vendors have been
integrated into production in terms of using kanban containers,
making frequent (or just-in-time) delivery and quality
certification.
3. Kanban/Pull System: Whether or not the plant has implemented
the physical elements of kanban/pull system.
4. Setup Time Reduction: Measures whether the plant is taking
measures to reduce setup times and lower lot sizes in order to
facilitate JIT.
5. Repetitive Nature of Master Schedule: Use of small lot sizes,
mixed model assembly, and a level daily production schedule in
the plant.
Implement JIT:
1. Kanban system.
2. Production Scheduling.
3. Set-up times.
4. Lot sizes Analysis.
5. Lead time Analysis.
6. Preventive maintenances Analysis.
7. Workforce and Organisational Culture.
8. Demand Management Analysis.
9. Inventory Management Analysis.
10. Inventory turnover.
11. Supplier delivery performance Analysis.
12. Implementation analysis. Ex. 5S.
13. Communication resources.
JIT quantitative Benefits, such as:
 Better quality products.
 Quality the responsibility of every worker, not just quality control
inspectors.
 Reduced scrap and rework.
 Reduced cycle times.
 Lower setup times.
 Smoother production flow.
 Less inventory, of raw materials, work-in-progress and finished
goods.
 Cost savings.
 Higher productivity.
 Higher worker participation.
 More skilled workforce, able and willing to switch roles. Etc.
Barriers:
 Lack of formal training/education for management and workers.
 Lack of cooperation with suppliers
 Obstacles to employee participation.
 Schedules may be more complex because changeovers are
frequent.
 Lack of accurate forecasting system.
The result of a JIT system is to "provide profit increase under slow growing
economy" by increasing the saleable production (the right mix, at the right
number at the right interface between accounting and manufacturing.
Conclusion:
To successes today, they must also be first in getting product and service to the
customer fast. JIT can be very effective and powerful as a means of
improvement. The JIT technique is a pull system rather than a push system,
based on not producing things until they are needed. Manufactures using JIT
processes want to use materials for production at levels that meet distributor or
retailer demand but not in excess.
The great weakness of this system is that no one can predict the future with
sufficient certainty, even with a complete and perfect understanding of the past
and a good sense of current trends in the marketplace.
Future scope of Just in Time (JIT) to bench mark or to study more
manufacturing, automobile companies so the result can be generated it helps to
improving productivity as well as Overall Equipment Efficiency (OEE).
It is concluded that the implementation of JIT system, the positive outcomes
that arise from the use of the system is far greater than those that are not.
Reference:
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Production Engineering and Metallurgy University of Technology
Baghdad – Iraq, 2014-2015.
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Information Processing Perspective” Boston university.
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