JustInTime Manufacturing b What is JIT Manufacturing b
Just-In-Time Manufacturing? b What is JIT Manufacturing? b Where did it come from? b What are the main principles? b Is it easy to Implement? b What phrase best describes JIT?
Just-In Time Manufacturing b JIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality. b JIT- operational management approach to achieve world class manufacturing. b JIT- production is based on demand
History of JIT Manufacturing b Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. b Toyota Motor Company- Birthplace of the JIT Philosophy Under Taiichi Ohno. • W. Edwards Deming • 14 points for Management b JIT is now on the rise in American Industries.
Principles Of JIT Manufacturing b Total Quality Management b Production Management b Supplier Management b Inventory Management b Human Resource Management
Principles Of JIT Manufacturing b Total Quality Management b Production Management b Supplier Management b Inventory Management b Human Resource Management
Total Quality Management b Seek long-term commitment to quality efforts with continuous improvement b Quality must be a higher priority than cost b Minimizing waste
Total Quality Management b Eliminate Quality Inspectors b Quality is everyone’s responsibility b Do it right the first time
Principles Of JIT Manufacturing b Total Quality Management b Production Management b Supplier Management b Inventory Management b Human Resource Management
Production Management b Pull System vs. Push System • Pull = Made to order • Push = Made for inventory b Flexability of the system b Design For Testability – In the process • Poka-Yoke= Mistake-proofing • Throughout entire process
Production Management b Reduced lot sizes= Shorter cycle times b Eliminate disruptions in the process b Standardized Parts/ Simplicity
Production Management b Communication Techniques • Completion of task-Kanban • Problem- Andon or siren/light b Stopping the process if something goes wrong =Jidoka b Preventive Maintenance
Production Management at Toyota Ø Toyota uses a Kanban pull system throughout the production process. Ø Each task in the process seems to take identical length and work content, so everyone is working at the same pace to reduce bottlenecks.
Principles Of JIT Manufacturing b Total Quality Management b Production Management b Supplier Management b Inventory Management b Human Resource Management
Supplier Management b Establish Long Term Relationships with few suppliers. b Delivery of Parts = 100% Defect Free • Where they are needed • When they are needed • The exact quantity b Work Together
Supplier Management b Elimination inspection of parts b Information Systems • Eliminating barriers to information b Communicate problems to suppliers in a positive manner.
Supplier Relations at Toyota Ø Toyota communicates their damand for parts 20 days in advance to their suppliers, with the right to change the forecast up to the 10 th day.
Principles Of JIT Manufacturing b Total Quality Management b Production Management b Supplier Management b Inventory Management b Human Resource Management
Inventory Management b Eliminate Safety Stock = Zero Inventory b Reduce WIP b JIT is not an inventory control system b Reduction in inventory opens up space
Inventory hides problems in a process. Water Level = Inventory Rocks = Problems in the system Boat = Company Operations
Principles Of JIT Manufacturing b Total Quality Management b Production Management b Supplier Management b Inventory Management b Human Resource Management
Human Resource Management b Company-wide Involvement • Motivation for continuous improvement • Problem Solving • High Employee Interaction b Build Pride In Workmanship
Human Resource Management b Self-Inspection of work b Diversified Employees • • b Absenteeism To eliminate boredom in process Management Support and Empowerment of workforce
Human Resource Management at Toyota Ø In 1986 from a labor force of 60, 000 Toyota received 2. 6 million improvement proposals, 96% of which were implemented by either management or the employees themselves.
WIP Example
Implementation Problems b Worker resistance b Lack of top management support b Lack of communication b Lack of formal training
Most Important Question b What phrase best describes the philosophy? Just-In-Time Continuous Improvement
Summary JIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality.
References Cammaranano, J. Lessons to be Learned: JIT. Atlanta, Georgia: Engineering and Management Press, 1997. Dear, A. Working toward JIT: Management Technology. London: Derek Doyle and Associates, 1988. Fisher, D. The JIT Self Test: Success Through Assesment and Implementation. Chicago, IL: Irwin Inc. , 1995. Hernandez, A. JIT Quality: A Practical Approach. Englewood Cliffs, NJ: Prentice-Hall, 1993. Hutchins, D. Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988. O’Grady, P. J. Putting the JIT Philosophy Into Practice. New York, NY: Nichols Publishing, 1988. Reinfeld, N. V. Handbook of Production and Inventory Control. Englewood Cliffs, NJ: Prentice-Hall, 1987. Schneiderjans, M. J. Advanced Topics In JIT Management: JIT Systems. Westport, CT: Greenwood Publishing Group, 1999. Taver, R. W. Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Problem Solving Process. New York, NY: AMACON, 1995. Wesner, J. W. , Hiatt, J. M. , and Trimble, D. C. Winning with Quality: Applying Quality Principles in Product Development. Reading, MASS: Addison-Wesley Publishing Co. , 1995.
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