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Just-In-Time Just-In-Time ManufacturingManufacturing
Just-In-Time Just-In-Time Manufacturing?Manufacturing?
What is JIT Manufacturing?What is JIT Manufacturing?
Where did it come from?Where did it come from?
What are the main principles?What are the main principles?
Is it easy to Implement?Is it easy to Implement?
What phrase best describes JIT?What phrase best describes JIT?
Just-In Time Just-In Time ManufacturingManufacturing
JITJIT- A philosophy of - A philosophy of continuous continuous improvementimprovement that puts emphasis on that puts emphasis on prevention rather than correction, and prevention rather than correction, and demands a company wide focus on demands a company wide focus on quality.quality.
JITJIT- operational management approach - operational management approach to achieve world class manufacturing. to achieve world class manufacturing.
JITJIT- production is based on demand- production is based on demand
History of JIT History of JIT ManufacturingManufacturing
Evolved in Japan after World War II, as a Evolved in Japan after World War II, as a result of their diminishing market share result of their diminishing market share in the auto industry. in the auto industry.
Toyota Motor CompanyToyota Motor Company- Birthplace of - Birthplace of the JIT Philosophy Under Taiichi Ohno.the JIT Philosophy Under Taiichi Ohno.• W. Edwards DemingW. Edwards Deming• 14 points for Management14 points for Management
JIT is now on the rise in American JIT is now on the rise in American Industries.Industries.
Principles Of JIT Principles Of JIT ManufacturingManufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Principles Of JIT Principles Of JIT ManufacturingManufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Total Quality Total Quality ManagementManagement
Seek long-term commitment to Seek long-term commitment to quality efforts with continuous quality efforts with continuous improvement improvement
Quality must be a higher priority Quality must be a higher priority than costthan cost
Minimizing wasteMinimizing waste
Total Quality Total Quality ManagementManagement
Eliminate Quality InspectorsEliminate Quality Inspectors
Quality is everyone’s responsibilityQuality is everyone’s responsibility
Do it right the first timeDo it right the first time
Principles Of JIT Principles Of JIT ManufacturingManufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Production ManagementProduction Management Pull System vs. Push SystemPull System vs. Push System
• Pull = Made to orderPull = Made to order• Push = Made for inventoryPush = Made for inventory
Flexability of the systemFlexability of the system
Design For Testability – In the processDesign For Testability – In the process Poka-Yoke= Mistake-proofingPoka-Yoke= Mistake-proofing Throughout entire processThroughout entire process
Production ManagementProduction Management
Reduced lot sizes= Shorter cycle Reduced lot sizes= Shorter cycle timestimes
Eliminate disruptions in the processEliminate disruptions in the process
Standardized Parts/ SimplicityStandardized Parts/ Simplicity
Production ManagementProduction Management
Communication TechniquesCommunication Techniques• Completion of taskCompletion of task-Kanban -Kanban • ProblemProblem- Andon or siren/light- Andon or siren/light
Stopping the process if something Stopping the process if something goes wrong =Jidokagoes wrong =Jidoka
Preventive MaintenancePreventive Maintenance
Production Management Production Management at Toyotaat Toyota
Toyota uses a Kanban pull system Toyota uses a Kanban pull system throughout the production process.throughout the production process.
Each task in the process seems to Each task in the process seems to take identical length and work take identical length and work content, so everyone is working at content, so everyone is working at the same pace to reduce the same pace to reduce bottlenecks.bottlenecks.
Principles Of JIT Principles Of JIT ManufacturingManufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Supplier ManagementSupplier Management Establish Long Term Relationships with Establish Long Term Relationships with
few suppliers.few suppliers.
Delivery of Parts = 100% Defect FreeDelivery of Parts = 100% Defect Free Where they are neededWhere they are needed When they are neededWhen they are needed The exact quantity The exact quantity
Work TogetherWork Together
Supplier ManagementSupplier Management
Elimination inspection of parts Elimination inspection of parts
Information SystemsInformation Systems Eliminating barriers to information Eliminating barriers to information
Communicate problems to suppliers Communicate problems to suppliers in a positive manner. in a positive manner.
Supplier Relations at Supplier Relations at ToyotaToyota
Toyota communicates their damand Toyota communicates their damand for parts 20 days in advance to their for parts 20 days in advance to their suppliers, with the right to change suppliers, with the right to change the forecast up to the 10the forecast up to the 10thth day. day.
Principles Of JIT Principles Of JIT ManufacturingManufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Inventory ManagementInventory Management
Eliminate Safety Stock = Zero Eliminate Safety Stock = Zero InventoryInventory
Reduce WIPReduce WIP
JIT is not an inventory control systemJIT is not an inventory control system
Reduction in inventory opens up spaceReduction in inventory opens up space
Inventory hides problems in Inventory hides problems in a process.a process.
Water Level = InventoryWater Level = Inventory
Rocks = Problems in the Rocks = Problems in the systemsystem
Boat = Company OperationsBoat = Company Operations
Principles Of JIT Principles Of JIT ManufacturingManufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Human Resource Human Resource ManagementManagement
Company-wide InvolvementCompany-wide Involvement Motivation for continuous improvementMotivation for continuous improvement Problem SolvingProblem Solving High Employee InteractionHigh Employee Interaction
Build Pride In WorkmanshipBuild Pride In Workmanship
Human Resource Human Resource ManagementManagement
Self-Inspection of workSelf-Inspection of work
Diversified EmployeesDiversified Employees AbsenteeismAbsenteeism To eliminate boredom in processTo eliminate boredom in process
Management Support and Empowerment Management Support and Empowerment of workforceof workforce
Human Resource Human Resource Management at ToyotaManagement at Toyota
In 1986 from a labor force of 60,000 In 1986 from a labor force of 60,000 Toyota received 2.6 million Toyota received 2.6 million improvement proposals, 96% of improvement proposals, 96% of which were implemented by either which were implemented by either management or the employees management or the employees themselves. themselves.
WIP Example WIP Example
Implementation Implementation ProblemsProblems
Worker resistanceWorker resistance
Lack of top management supportLack of top management support
Lack of communicationLack of communication
Lack of formal trainingLack of formal training
Most Important QuestionMost Important Question What phrase best describes the What phrase best describes the
Just-In-Time philosophy? Just-In-Time philosophy?
Continuous Continuous ImprovementImprovement
SummarySummary
JITJIT- A philosophy of - A philosophy of continuous continuous improvementimprovement that puts emphasis on that puts emphasis on prevention rather than correction, prevention rather than correction, and demands a company wide focus and demands a company wide focus on quality.on quality.
ReferencesReferences
Cammaranano, J. Cammaranano, J. Lessons to be Learned: JIT.Lessons to be Learned: JIT. Atlanta, Georgia: Engineering and Atlanta, Georgia: Engineering and Management Press, 1997.Management Press, 1997.
Dear, A. Dear, A. Working toward JIT: Management Technology.Working toward JIT: Management Technology. London: Derek Doyle and London: Derek Doyle and Associates, 1988.Associates, 1988.
Fisher, D. Fisher, D. The JIT Self Test: Success Through Assesment and Implementation.The JIT Self Test: Success Through Assesment and Implementation. Chicago, Chicago, IL: Irwin Inc., 1995. IL: Irwin Inc., 1995.
Hernandez, A. Hernandez, A. JIT Quality: A Practical Approach.JIT Quality: A Practical Approach. Englewood Cliffs, NJ: Prentice-Hall, Englewood Cliffs, NJ: Prentice-Hall, 1993.1993.
Hutchins, D. Hutchins, D. Just-In-Time: Inventory Control.Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988. Brookfield, VT: Gower Publishing, 1988.O’Grady, P.J. O’Grady, P.J. Putting the JIT Philosophy Into Practice.Putting the JIT Philosophy Into Practice. New York, NY: Nichols New York, NY: Nichols
Publishing, 1988.Publishing, 1988.Reinfeld, N.V. Reinfeld, N.V. Handbook of Production and Inventory Control.Handbook of Production and Inventory Control. Englewood Cliffs, NJ: Englewood Cliffs, NJ:
Prentice-Hall, 1987.Prentice-Hall, 1987.Schneiderjans, M.J. Schneiderjans, M.J. Advanced Topics In JIT Management: JIT Systems.Advanced Topics In JIT Management: JIT Systems. Westport, CT: Westport, CT:
Greenwood Publishing Group, 1999.Greenwood Publishing Group, 1999.Taver, R.W. Taver, R.W. Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step
Problem Solving ProcessProblem Solving Process. New York, NY: AMACON, 1995.. New York, NY: AMACON, 1995.Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Winning with Quality: Applying Quality Winning with Quality: Applying Quality
Principles in Product Development. Principles in Product Development. Reading, MASS: Addison-Wesley Publishing Co., Reading, MASS: Addison-Wesley Publishing Co., 1995.1995.
