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Just-in-Time SystemsJust-in-Time Systems

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Topics to be CoveredTopics to be Covered

Review of JIT & WasteObjectives of JIT

JIT Principles

Characteristics of jit

Benefit

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What is JIT?What is JIT?

a corporate system designed toproduce output within the minimum

lead time and at the lowest total cost bycontinuously identifying and eliminatingall forms of corporate waste andvariance.

a corporate strategy

a philosophy

Focus of JIT:

variance & waste

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Seven Basic Types ofSeven Basic Types of

WasteWaste

Transportation waste

Process Waste

Inventory WasteWaste of motion

Waste from product defects

Waiting timeOverproduction

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Common Causes of WasteCommon Causes of Waste

Layout (distance)

Long setup time

Incapable

processesPoor

maintenance

Poor workmethods

Lack of training

Inconsistentperformancemeasures

Ineffectiveproductionplanning

Lack ofworkplaceorganization

Poor supplyquality/reliability

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Objective of JITObjective of JIT

Produce only the products thecustomer wants.

Produce products only at the ratethat the customer wants them.

Produce with perfect quality

Produce with minimum lead time.

Produce products with only thosefeatures the customer wants.

Faster reaction to demand change

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ObjectivesObjectives

Produce with no waste of labor,material or equipment -- everymovement must have a purpose

so that there is zero idleinventory.

Produce with methods that allow

for the development of people

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JIT PrinciplesJIT Principles

Create flow production

one piece flow

machines in order of processes

small and inexpensiveequipment

U cell layout, counterclockwise

multi-process handling

workers

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JIT Principles - Slide 2JIT Principles - Slide 2

Establish TAKT time

rate at which the customerbuys a product

Build Pull Product

use of kanban system

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Benefits

Inventory costs are reduced

Material flow improvementReduced production lead time

Product quality is improvea and cost

of scrap is reduced

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Points to be considerd to made jiteffective

Multiple skill

Stablize master plan schedule

Small EOQ

Defect free material

Items should be present at time

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JIT TacticsJIT Tactics

Single MinuteExchange of Dies(SMED)

Statistical Process

ControlUse of standard

containersDoable stable

schedules with

adequate visibilityTAKT-Time5-S ProgramKaizen Event

Visual control

Flexible workers

Tools at the point ofneed

Product redesign

Group Technology

Total Productive

Maintenance

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Balanced ProductionBalanced Production

Three elements

TAKT time

Work sequence Standard WIP

Objective

Build at rate that the customer wantswork

Balance the system to maximize

efficiency at this rate

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SMEDSMED

Setup reductionElements

Internal Setup setup while machine idle

External Setup

setup while machine busy

Adjustment

run-ins, calibration

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Limitations of JITLimitations of JIT

Preconditions to JIT trust must be present

labor/management

suppliers/consumers recognition of processes

familiarity with problem solving

quality at the source

agreement over value and waste

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Limitations of JITLimitations of JIT

Right Settings applicable in growth to maturity

phases of

Product Life Cycle

standard product

Steinway and JIT

standard/fixed pay-rate

problems with piece-rate schemeUniversal agreement that change

needed

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Theoretical Benefits of JITTheoretical Benefits of JIT

Unpleasantsurprises

eliminatedLess

computerization

visual control

Improved quality

WIP reduced

Better

communications

Less pressure onreceiving docks and

incoming inspectionareas

Lower costs

Change in attitude

Defects aretreasures

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The 5-S ProgramThe 5-S Program

Seiri

segregate and discard

get rid of what is not neededSeiton

arrange and identify for ease of use

a place foreverything and everythingin its place

Seiso

Clean Daily

clean work place enhances quality

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The 5-S ProgramThe 5-S Program

Seiketsu

Revisit frequently

revisit the first 3 steps to maintainworkplace safety and effectiveness

Shitsuki

Motivate to sustain promote adherence through visual

performance measurement tools