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.

• JIT philosophy means getting the right quantity of goods at the right place and the right time • JIT exceeds the concept of inventory reduction; it is an all-encompassing philosophy geared to eliminate waste, anything that does not add value • A broad JIT view – or lean production/lean systems - is one that encompasses the entire organization

• JIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality. • JIT- operational management approach to achieve world class manufacturing. • JIT- production is based on demand. • JIT in time is a key element of lean production

• JIT meansi- producing the quantity of units that is needed.

Ii-producing them on the date-time required.

iii-Supplier delivers the exact quantity demanded at the scheduled time and date.

JIT Means … • • • • •

Keeping work flows moving Eliminating inventories Reducing travel distances Eliminating defects and scrap Maximizing usage of space

HOW IT WORKS?

History • Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. • Toyota Motor Company- Birthplace of the JIT Philosophy Under Taiichi Ohno. • JIT is now on the rise in American Industries.

Philosophy of Just-in-Time

• JIT originated in Japan at Toyota Motor Co, fueled by a need to survive after the destruction of post WWII • JIT gained worldwide prominence in the 1970s • Often termed “Lean Production” or “Lean Systems” • Broad view that entire organization has the same goal - to serve customers

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The Philosophy of JIT

• JIT is built on simplicity - simpler is better. • Continuous improvement • Visibility – all waste must be visible to be identified and eliminated • Flexibility - to adapt to changes in environment 9

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

Seven Wastes Shiego Shingo, a Japanese JIT authority and engineer at the Toyota Motor Company identified seven wastes as being the targets of continuous improvement in production process. By attending to these wastes, the improvement is achieved. 1. Waste of over production eliminate by reducing set-up times, synchronizing quantities and timing between processes, layout problems. Make only what is needed now. 2. Waste of waiting eliminate bottlenecks and balance uneven loads by flexible work force and equipment. 3. Waste of transportation establish layouts and locations to make handling and transport unnecessary if possible. Minimize transportation and handling if not possible to eliminate. 4. Waste of processing itself question regarding the reasons for existence of the product and then why each process is necessary.

5. Waste of stocks reducing all other wastes reduces stocks. 6. Waste of motion study for economy and consistency. Economy improves productivity and consistency improves quality. First improve the motions, then mechanize or automate otherwise. There is danger of automating the waste. 7. Waste of making defective products develop the production process to prevent defects from being produced, so as to eliminate inspection. At each process, do not accept defects and makes no defects. Make the process fail-safe. A quantify process always yield quality product.

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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 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

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

INVENTORY MANAGEMENT  Eliminate Safety  Inventory is

Stock = Zero Inventory

Evil

Water = Inventory

Material handling

Poor training

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.

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

REQUIREMENTS OF JIT

REQUIREMENTS OF JIT • Respond to Customer Requirements • Integrate all Processes • Employee Participation • Company wide Commitment to education • Eliminate idleness • 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

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 Downloaded from www.sfawade.com & www.fawade.wapka.me