Just in time

JUST-IN-TIME PHILOSOPHY

Yashpal Ghate (M-11-16)

Just in time………….

Just In Time

Keeping work flows moving

Eliminating inventories

Reducing travel distances

Eliminating defects and scrap

Maximizing usage of space

• Just-In-Time is a Japanese manufacturing

management method that was developed in the

1970’s.

• It was first adopted by Toyota manufacturing

plants by Taiichi Ohno.

• Producing only what is needed, when it is needed

(not early, not late; not less, not more)

Just In Time

• A management philosophy of continuous and

forced problem solving by attacking the root

causes.

• A highly coordinated processing system in which

goods move through the system, and services are

performed, just as they are needed.

• Supplies and components are ‘pulled’ through the

system to arrive where they are needed when they

are needed (just-in-time)

Just In Time

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

Just In Time

Three Elements of JIT

Three Elements of JIT

• JIT manufacturing focuses on production system

to achieve value-added manufacturing

• TQM is an integrated effort designed to improve

quality performance at every level

• Respect for people rests on the philosophy that

human resources are an essential part of JIT

philosophy

GOAL OF JIT

Goal of JIT

Product Design

ProcessDesign

PersonnelElements

Manufactur-ing Planning

Eliminate disruptions

Make the system flexible

Eliminate waste

Abalancedrapid flow

UltimateGoal

SupportingGoals

BuildingBlocks

• In order to achieve competitive

advantage through JIT, the necessary

building blocks should

be installed

• The building blocks can also be

regarded as JIT success factors.

JIT Building Blocks

• Product design

• Process design

• Organizational elements

• Manufacturing planning and

control

• Supplier relationships

• Preventive maintenance

JIT Building Blocks

Product Design

• Process design with product design

• Standard product configuration and

standart parts

• Reduced number of parts

• Modular design

• Concurrent engineering

• Highly capable production systems

Process Design

• Small lot sizes

• Setup time reduction

• Reduced Inventories (Limited WIP)

• Continuous quality improvement

• Production flexibility

• Balanced system

• Fail-safe methods

Organizational Elements

• Workers as assets

• Cross-trained workers

• Employee empowerment

• Continuous improvement

• Leadership management

• Commitment

Manufacturing Planning and Control

• Uniform production levels

• Level loading (level schedules)

• Pull systems

• Visual systems

• Reduced transaction processing

• Reduced number of vendors

• Supportive supplier relationships

• Quality deliveries on time

• Frequent deliveries in small lot quantities

• Reduced lead times

• Reduced transaction processing

• Certified vendors

Supplier Relationship

Preventive Maintenance• All activities involved in keeping equipment in

working order

• Maintaining equipment in good condition and

replacing parts that have a tendency to fail

before they actually fail

• Done to prevent failure

• JIT requires

– Scheduled & daily PM

– Operator involvement in PM

• Knows machines

• Responsible for product quality

Limitations of JIT

Preconditions to JIT

• Recognition of Processes

• Quality at the source

• Agreement over value and waste

• Trust must be present

- labor/management

- suppliers/consumers

• Management may not be committed

• Workers/management may not be cooperative

• May be difficult to change company culture

• Suppliers may resist

Obstacles in Conversion

• Unwilling to commit resources

• Uneasy about long-term commitments

• Frequent, small deliveries may be difficult

• Burden of quality control shifts to supplier

Supplier Resistance

• Use single-source suppliers when possible

• Build long-term relationships

• Work together to certify processes

• Co-locate facilities to reduce transport

if possible

• Stabilize delivery schedules

• Share cost & other information

.

Control over the Limitations

• Reduced inventory

• Improved quality

• Lower costs

• Reduced space requirements

• Reduced lead times

• Increased productivity

• Reduced scrap and rework

Benefits of JIT

• Better relations with suppliers

• Simplified scheduling and control activities

• Increased equipment utilization

• Better use of human resources

• More product variety

• Reduced need for indirect labor

Benefits of JIT