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A Presentation On :
JUST-IN-TIME MANUFACTURING BY ADNAN SHEIKH (2140778)
WHAT IS JIT?
JIT is a manufacturing philosophy involving an integrated set of procedures/activities designed to achieve a volume of production using minimal inventories. A highly coordinated processing system in which goods move through the system, and services are performed, just as they need.
History of JIT Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. Toyota Motor Company- first to implement fully functioning and successful JIT system, in 1970s. Japanese Manufacturers looked for a way to gain the most efficient use of limited resources. They worked on "optimal cost/quality relationship.
FOLLOWERS
Adopted by General Electrical in the USA in the
1980. Some companies referred JIT with different names: i.
TOYOTA Toyota System
ii. IBM Continuous flow manufacturing
iii. GE- Management by sight iv. HEWLETT- PACKARD- stockless production & repetitive manufacturing system
HOW IT WORKS?
JIT FUNCTIONS
Eliminates waste . Achieves streamlined production . Eliminate disruptions in production caused by poor quality, schedule changes, late deliveries. Makes the manufacturing delivery system flexible by allowing it to handle a variety of products and changes in the level of output. Reduces setup and delivery times .
7 WASTES
Waste of over production Waste of waiting Waste of transportation Waste of Underutilization of Employees Waste of Inventory Waste of motion Waste of making defective products
PRINCIPLES OF JIT PRODUCTION Total quality Management Production Management Supplier Management Inventory Management Human Resource Management
TOTAL QUALITY MANAGEMENT
Seek long-term commitment Quality must be a higher priority than cost Minimize Waste
PRODUCTION MANAGEMENT Pull System vs. Push System Pull = Made to order Push = Made for inventory
Communication Techniques Completion of task-Kanban Problem- Andon or siren/light
Flexibility of the system
Design For Testability Poka-Yoke= Mistake-proofing
SUPPLIER MANAGEMENT
E.g. Toyota Productions
Establish Long Term Relationships with few suppliers. Delivery of Parts = 100% Defect Free Where they are needed When they are needed The exact quantity
Work Toge
INVENTORY MANAGEMENT
Eliminate Safety Stock = Zero
Inventory Inventory is Evil
Water = Inventory
Material handling
Poor training
Traditional systems use
inventory (water) to buffer the process from problems (rocks) that cause disruption. Break downs
Material quality problems
Long setups
JIT systems view inventory as waste and work to
lower inventory levels to expose and correct the problems (rocks) that cause disruption.
Material handling
Poor training
Break downs
Material quality problems
Long setups
Lowering the level of inventory is relatively
easy to do. However, the problems that arise must be corrected quickly Otherwise, the process will flounder.
Material handling
Poor training
Material Break downs quality problems
Long setups
HUMAN RESOURCE MANAGEMENT Company-wide Involvement Motivation for continuous improvement Problem Solving
Diversified Employees Management Support and Empowerment of workforce
JIT MANUFACTURING BUILDING
BLOCKS Ultimate Goal
Supporting Goals
A balanced rapid flow
Reduce setup and lead times
Eliminate disruptions Make the system flexible
Product Design
Process Design
Eliminate waste Minimize inventories
Personnel Elements
Manufacturing Planning
REQUIREMENTS OF JIT Respond to Customer Requirements Integrate all Processes Employee Participation Company wide Commitment to education Eliminate redundancy Reduce all Inventory Establish Continuous Improvement Goals
Use a pull Production
System Design products for Manufacturing Develop Controllable Production Processes Have Defect Prevention Program Reduce Setup Times Build Products to Specification
OBSTACLES IN CONVERSION Management not committed Workers not cooperative Decide which parts need most effort Start by trying to reduce setup times Gradually convert operations Convert suppliers to JIT Prepare for obstacles Suppliers may resist
ADVANTAGES OF JIT High quality Flexibility Reduced setup times Reduced need for indirect labor Less waste Low warehouse cost Synchronization between production scheduling and work hour
DISADVANTAGES OF JIT
Time consuming No spare product to meet un expected order Supply Shock : If products do not reach on time High risk factor
JIT Not For Everyone
JIT concepts work best when goods can be produced in response to consumer demand (e.g. automobiles, etc.) JIT is less effective for the production of standardized consumer goods (e.g. basic clothing, food, soft drinks, toasters, etc.) There are cases where JIT concepts apply to subprocesses of a make to stock environment. (e.g. computers etc.)
