Published on February 21, 2014
JUST-IN-TIME MANUFACTURING A PowerPoint Presentation BY SWATI(54), MEENAL(39), REENU(45), JAYA(66)
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.
HOW IT WORKS?
HISTORY • Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. • Founded by Taiichi Ohno, a vice president of Toyota. • Basically implemented in Toyota plant 1950, well established after 1970.
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’
7 WASTES 1) 2) 3) 4) Waste of over production Waste of waiting Waste of transportation Waste of Underutilization of Employees 5) Waste of Inventory 6) Waste of motion 7) Waste of making defective products
PRINCIPLES OF JIT PRODUCTION
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 • Establish Long Term Relationships with few E.g. Toyota Productions suppliers. • Delivery of Parts = 100% Defect Free – Where they are needed – When they are needed – The exact quantity • Work Together • Elimination of inspection of parts
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 IN GOODS : • Leveraged JIT principles to make its manufacturing process a success • Leverage their suppliers to achieve the JIT goal • Provide exceptionally short set up times to their customers • Suppliers carry inventory instead of carrying it themselves. • Has dependable suppliers with the ability to meet its demanding lead time requirements.
• Seamless system that allows it to transmit its component on requirements • Willingness of suppliers to keep inventory on hand.
JIT IN SERVICES: MAC D McDonald’s is the best example of JIT in Services !
• McDonald's doesn't begin to cook until a customer has placed a specific order. • The major benefits are better food at a lower cost. • Wastage is reduced along with an improvised taste that makes you want to scream out I’m Lovin’ It !
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