Just in Time:by Sashi Prabhu

8/8/2019 Just in Time:by Sashi Prabhu

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JustJust--InIn--TimeTime

Eliminate WasteEliminate Waste


2/20

Flexible ResourcesFlexible Resources

Multifunctional workersMultifunctional workers

Operate more than one machine &Operate more than one machine &jobsjobs

GeneralGeneral--purpose machinespurpose machines

Machines that are not highlyMachines that are not highly

specializedspecialized


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Cellular LayoutsCellular Layouts

Manufacturing cellsManufacturing cells

Often UOften U--shaped or linearshaped or linear

Work flows through cell in oneWork flows through cell in onedirection and experiences littledirection and experiences littlewaitingwaiting


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Pull SystemPull System

Coordinating production andCoordinating production anddelivery of materials anddelivery of materials andcomponentscomponents

Traditionally, inventory has beenTraditionally, inventory has beenused as a cushion against lapses inused as a cushion against lapses in

coordination and inventory can becoordination and inventory can behugehuge

Pull system a la at USPull system a la at US

supermarketssupermarkets


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Pull SystemPull System

Do not order more product thanDo not order more product thancan be usedcan be used

(or items that can be sold)(or items that can be sold)

Reversal of normal Reversal of normal pushpush systemsystem


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Kanban Production ControlKanban Production Control

SystemSystem Japanese word for cardJapanese word for card

Associated with fixedAssociated with fixed--qu

antityqu

antityinventory systeminventory system

TwoTwo--bin systembin system KanbanKanban


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SmallSmall--Lot ProductionLot Production

Requires less space and capitalRequires less space and capital

Produces small amounts at a timeProduces small amounts at a time

Processes can be moved closerProcesses can be moved closertogethertogether

Transportation between stations isTransportation between stations is

simplifiedsimplified Quality problems are easier toQuality problems are easier to

detectdetect

Reveals errors and bottlenecksReveals errors and bottlenecks


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Lead TimeLead Time

Processing timeProcessing time

Can be reduced by reducing numberCan be reduced by reducing numberof items processed and the efficiencyof items processed and the efficiencyor speed of the workeror speed of the worker

Move timeMove time

Can be decreased if machines areCan be decreased if machines aremoved closer together, method ofmoved closer together, method ofmovement simplified, routings aremovement simplified, routings arestandardized, or need for movementstandardized, or need for movement

eliminatedeliminated


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Lead TimeLead Time

Waiting TimeWaiting Time

Can be reduced through betterCan be reduced through betterscheduling of materials, workers,scheduling of materials, workers,machines and sufficient capacitymachines and sufficient capacity

Setup TimeSetup Time

Reduction of setup time is importantReduction of setup time is importantto JITto JIT


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Quick SetupsQuick Setups

Streamline all aspects of setupStreamline all aspects of setup

Organize workplace properly locating toolsOrganize workplace properly locating tools

near points ofusenear points ofuse Keep machines and fixtures in good repairKeep machines and fixtures in good repair

Simplify or eliminate adjustmentsSimplify or eliminate adjustments

precoding desired settings, using locator pins,precoding desired settings, using locator pins,

etc.etc. Perform setup activities in parallel orPerform setup activities in parallel or

eliminateeliminate

Add a person, standardize components,Add a person, standardize components,

parts, materialsparts, materials


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Uniform Production LevelsUniform Production Levels

Smoothing productionSmoothing productionrequirements on the final assemblyrequirements on the final assembly

lineline

Better forecastBetter forecast

Mixed production throughout the dayMixed production throughout the day

in small quantities on all productionin small quantities on all productionfacilities.facilities.


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Qualityat the SourceQualityat the Source

For JIT to work, quality has to beFor JIT to work, quality has to behighhigh

No extra inventory to bufferNo extra inventory to bufferagainst defective unitsagainst defective units

Producing poorProducing poor--quality items andquality items and

reworking items or rejecting them isreworking items or rejecting them iswastefulwasteful

Workers are responsible forWorkers are responsible for

inspectioninspection


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JidokaJidoka Authority to stop production line ifAuthority to stop production line if

quality problems are encounteredquality problems are encountered AndonsAndons

Call lights activated by switchesCall lights activated by switches

Undercapacity schedulingUndercapacity schedulingMaking time to plan, train, solveMaking time to plan, train, solve

problems, maintain workproblems, maintain workenvironmentenvironment


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Visual controlVisual control

Quality improves when problems areQuality improves when problems are

made visible and workers have clearmade visible and workers have clearexpectations of performanceexpectations of performance

Kanbans, andons, process controlKanbans, andons, process control

charts, tool boards, material handlingcharts, tool boards, material handlingroutes clearly marked, demos,routes clearly marked, demos,instructional photos, performanceinstructional photos, performancedatadata


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PokaPoka--yokeyoke

Foolproof device or mechanism thatFoolproof device or mechanism that

prevents defects from occurringprevents defects from occurring

KaizenKaizen

Continuous improvementContinuous improvement


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TotalProductive MaintenanceTotalProductive Maintenance

Breakdown maintenanceBreakdown maintenance

Preventive maintenancePreventive maintenance

Total Productive MaintenanceTotal Productive Maintenance Accurate records on time betweenAccurate records on time between

breakdownsbreakdowns

Frequency of breakdownsFrequency of breakdowns

Costs of breakdownsCosts of breakdowns Determine a preventive maintenanceDetermine a preventive maintenance

scheduleschedule

Employee involvementEmployee involvement

Zero defectsZero defects


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Supplier NetworksSupplier Networks

Working with suppliers to improveWorking with suppliers to improveresponsiveness and qualityresponsiveness and quality

Trends:Trends: Locate near the factoryLocate near the factory

Use small, sideUse small, side--loaded trucks and ship mixed loadsloaded trucks and ship mixed loads

Consider establishing small warehouses near to theConsider establishing small warehouses near to thefactory.factory.

Use standardized containers and make deliveriesUse standardized containers and make deliveries

according to a precise delivery scheduleaccording to a precise delivery schedule Become a certified supplier and accept payment atBecome a certified supplier and accept payment at

regular intervals rather than upon deliveryregular intervals rather than upon delivery


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Benefits of JITBenefits of JIT

Reduced inventoryReduced inventory

Improved qualityImproved quality

Lower costsLower costs

Reduced space requirementsReduced space requirements

Shorter lead timeShorter lead time Increased productivityIncreased productivity


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Benefits of JITBenefits of JIT

Greater flexibilityGreater flexibility

Better relations with suppliersBetter relations with suppliers

Simplified scheduling and controlSimplified scheduling and controlactivitiesactivities

Increased capacityIncreased capacity

Better use of human resourcesBetter use of human resources

More product varietyMore product variety

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Just in Time:by Sashi Prabhu