1. JIT/Lean Production
• Just-in-time
(JIT): A highly coordinated
processing system in which goods move
through the system, and services are
performed, just as they are needed
•
Highly Coordinated, Repetitive manufacturing
designed to produce high volumes with fewer
resources.
•
Developed by Taiichi Ohno

2. JIT
Produce and deliver goods just in time to be sold,
Subassemblies just in time to be assembled into
FP and purchase material just in time to be
transformed into fabricated parts.
• A production system to produce the kind of units
needed at the time needed and in the quantities
needed.
•

3. Goal of JIT
The ultimate goal of JIT is a balanced
system.
Achieves a smooth, rapid flow of materials
through the system
Pursue a system with min. inventories,
space, waste and min. transactions

4. Summary JIT Goals and Building Blocks
Ultimate
A
Goal balanced
rapid flow
Supporting
Goals
Eliminate disruptions
Make the system flexible
Product
Design
Process
Design
Eliminate waste
Personnel
Elements
Manufacturing Planning
Building
Blocks

5. Supporting Goals
•
Eliminate disruptions
•
Make system flexible
•
Eliminate waste, especially excess
inventory

6. Sources of Waste
•
Overproduction
•
Waiting time
•
Unnecessary transportation
•
Processing waste
•
Inefficient work methods
•
Product defects

7. JIT Building Blocks
•
Product design
•
Process design
•
Personnel/organizational
elements
•
Manufacturing
planning and control

8. Product Design
•
Standard parts
•
Modular design
•
Highly capable production systems
•
Concurrent
engineering

9. Process Design
•
Small lot sizes
•
Setup time reduction
•
Manufacturing cells
•
Limited work in process
•
Quality improvement
•
Production flexibility
•
Little inventory storage

10. Benefits of Small Lot Sizes
Reduces inventory
Less rework
Less storage space
Problems are more apparent
Increases product flexibility
Easier to balance operations

11. Production Flexibility
•
Reduce downtime by reducing
changeover time
•
Use preventive maintenance to reduce
breakdowns
•
Cross-train workers to help clear
bottlenecks

12. Production Flexibility (cont’d)
Use many small units of capacity
• Use off-line buffers
• Reserve capacity for important customers
•

13. Quality Improvement
•
Autonomation
•
Automatic detection of defects during
production

14. Personnel/Organizational Elements
•
Workers as assets
•
Cross-trained workers
•
Continuous
improvement
•
Cost accounting
•
Leadership/project
management

15. Manufacturing Planning and Control
•
Pull systems
•
Visual systems
•
Close vendor relationships
•
Reduced transaction
processing
•
Preventive maintenance

17. Pull/Push Systems
•
Pull system: System for moving work where
a workstation pulls output from the preceding
station as needed. (e.g. Kanban)
•
Push system: System for moving work where
output is pushed to the next station as it is
completed

18. Kanban Production Control System
•
Kanban: Card or other device that
communicates demand for work or materials
from the preceding station
•
Kanban is the Japanese word meaning
“signal” or “visible record”
•
Paperless production control system
•
Authority to pull, or produce comes
from a downstream process.

19. Traditional Supplier Network
Buyer
Buyer
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier

20. Tiered Supplier Network
Buyer
Buyer
First Tier Supplier
Second Tier Supplier
Third Tier Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier

21. Comparison of JIT and Traditional
Factor
Traditional
JIT
Inventory
Much to offset forecast
errors, late deliveries
Minimal necessary to operate
Deliveries
Few, large
Many, small
Lot sizes
Large
Small
Setup; runs
Few, long runs
Many, short runs
Vendors
Long-term relationships
are unusual
Partners
Workers
Necessary to do the
work
Assets

22. Transitioning to a JIT System
•
Get top management commitment
•
Decide which parts need most effort
•
Obtain support of workers
•
Start by trying to reduce setup times
•
Gradually convert operations
•
Convert suppliers to JIT
•
Prepare for obstacles

23. Obstacles to Conversion
•
Management may not be committed
•
Workers/management may not be
cooperative
•
Suppliers may
resist
•
Why?

24. JIT in Services
The basic goal of the demand flow technology in
the service organization is to provide optimum
response to the customer with the highest quality
service and lowest possible cost.
Eliminate disruptions
• Make system flexible
• Reduce setup and lead times
• Eliminate waste
• Minimize WIP
• Simplify the process
•

25. Kaizen (Continuous Improvement)

26. Kaizen (Continuous Improvement)
•
•
•
•
Japanese concept –
Focus on gradual and continuous improvement
A whole business philosophy
Importance of EVERYONE buying into the concept and
the vision

27. Kaizen
Great attention paid to customer
•Efficient stock control
requirements and needs
•
methods help reduce costs
and improve cash-flow
•Flexible working practices
and empowerment – help
increase efficiency, reduce
costs and improve
•Leadership seen as vital.
motivation
Ability to communicate a
clear vision, take people
•Fundamental principles –
along with the vision and
often characterised as ‘lean
to think about where the
production’ – reducing waste,
company needs to be in
zero defects, high quality
5, 10, 15 and 20 yearsdelivery,
•Punctuality in all aspects –
control measures at all stages
supply,
time manufacture, etc.

28. 5 S of Kaizen
Sort - the first step in making things
cleaned up and organized
• Set In Order - organize, identify and
arrange everything in a work area
• Shine - regular cleaning and maintenance
• Standardize - make it easy to maintain simplify and standardize
• Sustain -maintaining what has been
accomplished
•

29. Benefits of JIT Systems
•
Reduced inventory levels
•
High quality
•
Flexibility
•
Reduced lead times
•
Increased productivity

30. Benefits of JIT Systems (cont’d)
•
Increased equipment utilization
•
Reduced scrap and rework
•
Reduced space requirements
•
Pressure for good vendor relationships
•
Reduced need for indirect labor

31. Elements of JIT
Smooth flow of work (the ultimate goal)
• Elimination of waste
• Continuous improvement
• Eliminating anything that does not add
value
• Simple systems that are easy to manage
• Use of product layouts to minimize moving
materials and parts
• Quality at the source
•

32. Elements of JIT (cont’d)
Poka-yoke – fail safe tools and methods
• Preventative maintenance
• Good housekeeping
• Set-up time reduction
•
•
Cross-trained employees
•
A pull system