TALIB KHAN VIVEK GAUR MBA ALIGARH MUSLIM UNIVERSITY MALAPPURAM CENTRE Just Timemanufacturing In
Introduction Just-in-time manufacturing philosophy Elements of just in time manufacturing Benefits of Jit manufacturing Manufacturing JIT implementation conclusion
What is just-in-time manufacturingJit is philosophy of manufacturing based on planned elimination of all waste and continuous improvement of productivity it encompasses the successful execution of all manufacturing activities required to produce a final product from design engineering to delivery and including all the states of conversion from raw material onward.
The philosophy of JIT can be traced back to Henry Ford, but formalized JIT originated in Japan as the Toyota Production System. W. Edwards Deming’s lesson of variability reduction was a huge influence.JIT is a long-term approach to process improvement. It usestimeliness as a lever to lower costs, improve quality and improveresponsiveness. However, JIT requires enormous commitment. Ittook Toyota more than 25 years to get right! The focus of JIT is to improve the system of production by eliminating all forms of WASTE.
Eliminating wastes Total quality management Parallel processing Jit purchasing E-commerce and JIT purchasing Reducing inventories through setup reduction working towards repetitive manufacturing
Traditional Goal: maximize production by minimizing disruptions Management Assumption: we can sell what we makeJIT Goal: Produce salable goods as quickly and efficiently as possible Management Assumption: we make what we can sell
Just-in-Time PrinciplesTraditional Manufacturing Just-in-Time ManufacturingIncreases inventory to Reduces inventoryprotect against processproblemsIncreases lead time to Reduces lead timeprotect against uncertaintyDisregards setup time Reduces setup timeas an improvement priority
Traditional Manufacturing Just-in-Time ManufacturingEmphasizes work of Emphasizes team-individuals, following oriented employeemanager instructions involvementEmphasizes push Emphasizes pullmanufacturing manufacturingTolerates defects Emphasizes zero defects 8
Stabilize production schedule Increase production capacity of manufacturing Improve the product quality Cross train worker Reduce equipment breakdowns through preventive maintenance Develop long term relationship that avoid interruption to the material flows just in time by ravindra 2/22/2009 9
The main benefits of JIT are listed below. Set up times are significantly reduced in the factory. Cutting down the set up time to be more productive will allow the company to improve their bottom line to look more efficient and focus time spent on other areas that may need improvement. The flows of goods from warehouse to shelves are improved. Having employees focused on specific areas of the system will allow them to process goods faster instead of having them vulnerable to fatigue from doing too many jobs at once and simplifies the tasks at hand. Small or individual piece lot sizes reduce lot delay inventories which simplifies inventory flow and its management. Employees who possess multiple skills are utilized more efficiently. Having employees trained to work on different parts of the inventory cycle system will allow companies to use workers in situations where they are needed when there is a shortage of workers and a high demand for a particular product.
Better consistency of scheduling and consistency of employee work hours. If there is no demand for a product at the time, workers don’t have to be working. This can save the company money by not having to pay workers for a job not completed or could have them focus on other jobs around the warehouse that would not necessarily be done on a normal day. Increased emphasis on supplier relationships. No company wants a break in their inventory system that would create a shortage of supplies while not having inventory sit on shelves. Having a trusting supplier relationship means that you can rely on goods being there when you need them in order to satisfy the company and keep the company name in good standing with the public. Supplies continue around the clock keeping workers productive and businesses focused on turnover. Having management focused on meeting deadlines will make employees work hard to meet the company goals to see benefits in terms of job satisfaction, promotion or even higher pay.
Step 1: Awareness The goal of JIT is to eliminate waste in all its forms. The assumption of JIT is that we cannot sell everything we make. Thus, we must produce salable goods (low cost, high quality, etc...) quickly. Operation = Motion (Waste) + Work (Added Value) Motion alone is a waste that adds cost (counting things, moving boxes, transporting goods, preparation time, waiting, producing defects, over production, handling materials, switching things on) Inventory decouples individual operations and thereby creates waste (non- value-added motion) to buffer the operations against the effect of a different form of waste (long setups, poor material handling procedures, production of defects, etc.) For real improvement, we must ask "why" when we encounter any form of waste.
Step 2: Workplace Improvement (the 5 S’s) Seiri: Proper arrangement (sort through and sort out, identify what you need, discard what you do not need ) Seiton: Orderliness (assign a separate location for all essential items) Seiso: Cleanliness (keep the workplace spotless at all times) Seiketsu: Cleanup (maintain equipment and tools) Shitsuke: Discipline (stick to the rules scrupulously)
Step 3: Flow Manufacturing (one piece at a time) Place the machines in process sequence Design a cellular (U-shaped) layout Make one piece at a time in the cell Produce according to the cycle time Have the operators work standing up and walking Use slower, dedicated machines that are smaller and less expensive