Just in time

Manoj Lawate

Introduction

• “a philosophy of manufacturing based on planned elimination of all waste & on continuous improvement of productivity”

• a production strategy that strives to improve a business return on investment by reducing

1. in-process inventory 2. associated carrying costs

Just In Time!!! Air Traffic Control

Founder of JIT

• Founded by Taiichi Ohno • A vice president of

Toyota• Basically implemented

in Toyota plant 1950, well established after 1970

• Well known as Toyota Production System

Followers of JIT

• Adopted by General Electrical in the USA in the 1980

• Some companies referred JIT with different names;

– TOYOTA = ‘Toyota System’

– IBM = ‘continuous flow manufacturing’

– HEWLETT-PACKARD = ‘stockless production & repetitive manufacturing system’

– GE = ‘management by sight’

Some Statistics …

Comparison GM TOYOTA

Assembly Hours 40.7 Hours 16 Hours

Defects per 100 Hours 130 Defects 45 Defects

Average inventory level 2 Weeks 2 Hours

JIT Goals…

• Eliminate disruptions• Make the system flexible• Reduce set up times & lead time • Minimize inventory• Eliminate waste• Increase productivity• Give the customer the products they want, when

and where they want them at the minimum cost

Steps in JIT• Introduce the speed

design of process, target, use of recourses – 1000 cars in a month, 500 workers– 1000 cars in a week, 1500 workers

• Eliminate or Reduce Stock zero inventory level is ideal

• Examples of KANBAN involves a customer & a supplier aim = to satisfy the customer’s needs

Steps in JIT• Design of Plant arranging machinery, people & activities

• Reducing & Avoiding set ups & Preventive Maintenance

so that activity should not stopped

• Simplifying the planning so that replacement can be possible

Tools of JIT

• The 7 wastes• The 5 Ss• Kanban Inventory• Visual Control• Pokayoke• Kaizen• Cellular Work Flow• Standard Work Concept• Make it Ugly• Just Do It

The 7 Wastes

Waste according to JIT

Concluding JIT

• Advantage of JIT - reduces cost of production

• Disadvantage of JIT - it takes time to establish

Thank You!