Just in Time

Ahsan Ahmad Baba

Topics

Introduction

Objectives of JIT

Advantages of JIT

Kaizen Philosophy

Bottle necks in implementing Just in Time in India

JIT Building Blocks

Companies Following JIT

What is JIT?

Producing only what is needed, when it is

needed (not early, not late; not less, not more)

An integrated but simplified system.

Objectives of JIT?

Produce only the products the customer

wants.

Produce products only at the rate that the

customer wants them.

Produce with perfect quality

Produce with minimum lead time.

Produce products with only those features the

customer wants.

Produce with no waste of labor, material or

equipment -- every movement must have a

purpose so that there is zero idle inventory.

Advantages of JIT

Low Inventory levels and Funds that were tied up in

inventories can be used elsewhere.

Shorter production cycle time.

Improved Product Quality. Defect rates are reduced,

resulting in less waste and greater customer satisfaction.

Eliminates waste.

Areas previously used to store inventories can be used

for other more productive uses.

Kaizen Philosophy

A philosophy of never being satisfied

with what was accomplished earlier…

Kaizen is a Japanese philosophy for

process improvement that can be traced

to the meaning of the Japanese words

‘Kai’ and ‘Zen’, which translate roughly

into ‘to break apart and investigate’ and

‘to improve upon the existing situation

Kaizen means improvement, continuous

improvement involving everyone in the

organization from top management, to

managers then to supervisors, and to

workers.

The essence of Kaizen is that the people

that perform a certain task are the most

knowledgeable about that task;

consequently, by involving them and

showing confidence in their capabilities,

ownership of the process is raised to its

highest level.

Why we prefer Kaizen

Conventional Approach Vs. Process-

emphasis Approach

Conventional Approach Process-emphasis Approach (Kaizen)

1 Employees are the

problem

The process is the problem

2 Doing my job Helping to get things done

3 Measuring Individuals Measuring performance

4 Change the person Change the process

5 Who made the error What allowed tile error to occur?

Bottle necks in Implementing

Just in Time in India

A bottleneck in a process occurs when input comes in faster

than the next step can use it to create output. The term

compares assets (information, materials, products, man-

hours) with water. When water Is poured out of a bottle, it

has to pass through the bottle's neck, or opening. The

wider the bottle's neck, the more water (input/assets) you

can pour out. The smaller, or narrower, the bottle's neck,

the less you Can pour out – and you end up with a back-

up, or "bottleneck."

BOTTLENECKS:-

It takes a lot of time to give results initially.

Implementing thorough JIT procedures can involve a major overhaul of

business systems -it may be difficult and expensive to introduce.

An investment should be made in information technology to link the

computer systems of the company and its suppliers, so that they can

coordinate the delivery of parts and materials.

JIT implementation also depends on management-workers relations. The

two parties being at loggerheads don’t help the cause.

A company may not be able to immediately meet the

requirements of a massive and unexpected order, since it

has few or no stocks of finished goods.

JIT involves change. It has been found out that normally

people are resistant to change

JIT is best suited to only medium and high volume of

production.

JIT Building Blocks

1. Product design

2. Process design

3. Personnel/organizational Elements

4. Manufacturing Planning and Control

5. Supplier relationships

6. Preventive maintenance

1. Product Design

Process design with product design

Standard products.

Reduced number of parts

Balanced System.

2. Process DesignSmall lot sizes

Setup time reduction

Cellular layout (Manufacturing cells)

Reduced Inventories (Limited WIP)

Continuous quality improvement

Production flexibility (multifunctional workers, general purpose machines)

3. Personnel/Organizational ElementsWorkers as assets

Cross-trained workers

Employee empowerment

Continuous improvement

Leadership/project management

Commitment

4. Manufacturing Planning

and Control

Uniform production levels.

Level loading (level schedules)

Pull systems.

Visual systems.

Eliminating Waste

5. Supplier Relationships Close relation with suppliers because of low

inventory.

Generally utilize local suppliers.

Quality deliveries on time.

Frequent deliveries in small lot quantities

Reduced lead times. (Time between placing

of order and delivery of order)

Reduced number of suppliers.

Companies Following Just In time

Just in time is incomplete

without talking about Toyota

because it’s the company

where just in time was

developed between 1948

and 1975.

Thank You