Just In Time

1. 1
Just-in-Time Production Systems
This presentation explores:
– JIT philosophy
– JIT (pull) production control
– JIT and quality
– North American adaptations of JIT ....

2. 2
Just-In-Time Production
• Management philosophy
• Pull system though the plant
WHAT IT IS
• Employee participation
• Industrial engineering/basics
• Continuing improvement
• Total quality control
• Small lot sizes
WHAT IT REQUIRES
• Attacks waste
• Exposes problems and bottlenecks
• Achieves streamlined production
WHAT IT DOES
• Stable environment
WHAT IT ASSUMES
....
Exhibit 6.3

3. 3
JIT: Part Philosophy-Part Technique
“Big JIT” (Lean Production)
– Philosophical focus on elimination of all sources of
waste.
“Little JIT”
– Focuses more narrowly on scheduling goods inventories
and providing service resources where and when needed
....

4. 4
Waste Reduction (“Big JIT”)
Waste
Reduction
Material &
Inventory
Management
Vendor
Relations
Human
Relations
Technology
....

5. 5
Pull System (“Little JIT”)
Sub
Sub
Fab
Fab
Fab
Fab
Customers Final Assy
Vendor
Vendor
Vendor
Vendor
Exhibit 6.1
....

6. 6
Waste--Operations
(1) Waste from overproduction
(2) Waste of waiting time
(3) Transportation waste
(4) Inventory waste
(5) Processing waste
(6) Waste of motion
(7) Waste from product defects ....

7. 7
Minimizing Waste:
Focused Factory Networks
....
Coordination
System Integration
Final Assembly

8. 8
Minimizing Waste:
Group Technology
Departmental Specialization ....
Exhibit 6.2
Saw Saw
Lathe Press
Press
Grinder
1
2
3
4
5
6
Lathe
Lathe
Saw
Press
Heat Treat
Grinder

9. 9
Minimizing Waste:
Group Technology
Group technology cells ....
Exhibit 6.2
....
Press
Lathe
Grinder
Grinder
A
1 2
B
Saw
Heat Treat
Lathe
Saw Lathe
Press
Lathe

10. 10
Minimizing Waste:
Quality at the Source
Self-inspection
Automated inspection
Line-stopping empowerment ....

11. 11
Inventory Hides Problems
Exhibit 6.4
....
Work in
process
queues
(banks)
Change
orders
Engineering design
redundancies
Vendor
delinquencies
Scrap
Design
backlogs
Machine
downtime
Decision
backlogs
Inspection
backlogs
Paperwork
backlog

12. 12
Minimizing Waste:
JIT Production
Produce...
...what is needed...
...when it’s needed...
...NOTHING MORE! ....

13. 13
Minimizing Waste:
Uniform Plant Loading
This does not mean building a single product.
We need to maintain a stable mix of products,
and firm monthly schedules ....

14. 14
Minimizing Waste:
Kanban Production Control Systems
A
B
Machine Center Assembly Line
Storage
Production
Kanban
Withdrawal
Kanban
Exhibit 6.6
....

15. 15
Minimizing Waste:
Minimized Setup Times
What are the consequences of long setup times?
A requirement for small-lot-size, mixed-model
production? ....

16. 16
Respect for People
Level payrolls
Cooperative employee unions
Subcontractor networks
Bottom-round management style
Quality circles (Small group involvement activities)
....

17. 17
North American Modifications of JIT
Can JIT work in North America?
What are the cultural barriers to successful
implementation? ....

18. 18
HOW-TO: Design Flow Process
Link operations
Balance workstation capacities
Relayout for flow
Emphasize preventive maintenance
Reduce lot sizes
Reduce setup/changeover time ....
Exhibit 6.8

19. 19
HOW-TO: Total Quality Control
Worker responsibility
Measure SQC
Enforce compliance
Fail-safe methods
Automatic inspection ....

20. 20
HOW-TO: Stabilize Schedule
Level schedule
Underutilize capacity
Establish freeze windows ....

21. 21
HOW-TO: Kanban-Pull
Demand pull
Backflush
Reduce lot sizes ....

22. 22
HOW-TO: Work with Vendors
Reduce lead times
Frequent deliveries
Project usage requirements
Quality expectations ....

23. 23
HOW-TO: Reduce Inventory More
Stores
Transit
Carousels
Conveyors ....

24. 24
HOW-TO: Improve Product Design
Standard product configuration
Standardize and reduce number of parts
Process design with product design
Quality expectations ....

25. 25
Applying JIT Concepts
Organize Problem-Solving Groups
Upgrade Housekeeping
Upgrade Quality
Clarify Process Flows
Revise Equipment and Process Technologies ....

26. 26
Applying JIT Concepts
Level the Facility Load
Eliminate Unnecessary Activities
Reorganize Physical Configuration
Introduce Demand-Pull Scheduling
Develop Supplier Networks ....

27. 27
YOUR EXPERIENCES WITH TLA
WHAT HAS SUCCEEDED AT YOUR FIRM
WHAT HAS NOT SUCCEEDED
WHAT ARE POTENTIALAPPLICATION S
REFER TO EXHIBIT 6.8
ALSO REFER TO PREVIOUS LISTING

28. 28
TOO MANY TLA
TBC, JIT, TQM, BPR,TOC, ABC, ABM
THE LIST GOES ON
WHAT SHOULD A PERSON DO?
USE A CONTINGENCYAPPROACH
KNOW THE PRINCIPLES OF EACH TLA
APPLY THAT WHICH IS APPLICABLE
REMEMBER ALL TLA WILL EVENTUALLY BE
DISCREDITED ANYWAY.

29. 29
JIT BUILDING BLOCKS
DESIGN FLOW PROCESS
TQM
STABILIZE SCHEDULE
KANBAN PULL
WORK WITH SUPPLIERS
REDUCE INVENTORY MORE
IMPROVE PRODUCT DESIGN
CONCURRENLTYAPPLY SCIENC. METHOD