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Just
TimeIn
MEMBERS
SONAM JADIA PRIYANKA LALIT SHIKHA MEHRA JASLEEN NAKRA RUCHA PILGAONKAR
INTRODUCTION
Just-In-Time is “a philosophy of manufacturing based on planned elimination of all waste and on continuous improvement of productivity”.
Just-In-Time is a Japanese manufacturing management method developed in 1970s & was first adopted by Toyota manufacturing plants at Taiichi Ohno.
It is an approach for process improvement . It uses Timeliness as a lever to lower cost , improve quality & responsiveness.
Goals of JIT
Waste elimination
Respond tocustomer needs
Competitiveness
Reliable relationshipwith suppliers
Efficiency Optimal cost/qualityrelationship
Inc.productivity
Reduce costs
0 Defectprocess
Just-in-Time Principles
Increases inventory to protect against process problems
Reduces inventory
Increases lead time to protect against uncertainty
Reduces lead time
Disregards setup timeas an improvement priority
Reduces setup time
Emphasizes process-oriented layout
Emphasizes product-orientedlayout
Emphasizes work of individuals, following manager instructions
Emphasizes team-oriented employee involvement
Traditional Manufacturing Just-in-Time Manufacturing
Emphasizes push manufacturing
Emphasizes pull manufacturing
Tolerates defects Emphasizes zero defects
Treats suppliers as “arms-length,” independent entities
Emphasizes supplier partnering
Just-in-Time Principles cntd…
Traditional Manufacturing Just-in-Time Manufacturing
Elements of JIT
People Systems
Plant
JIT
People
Stockholders
Management
Labor
Govt support
System
MaterialRequirement Planning
ManufacturingResource Planning
computer basedbottom-up
manufacturing approachproduction plan
master production schedule
Plant Layout
DemandPull
Kanban
Continuousimprovement
Reduceinventory
Selfinspection
Plant
Kanban Kanban: Kan visual, Ban card/board It is a signaling system to trigger
action
Demand forecast
Customer demand
Push system
Pull system
Kanban cards
Information about itemIts specificationPreceding processSucceeding processQuantities of such items
Companies That Have Implemented JIT
JIT IN PRODUCTION SYSTEMS There are major differences
between the production systems. First, each production system is
designed to produce different numbers of products in different volumes.
Second, each system arranges its equipment in a different layout. The material flow is different because of that layout.
CONTD….
Third and most important, each provides different levels of output viz:
Cost Quality Performance Delivery Flexibility Innovativeness Output. The JIT production system can make
improvements in all the 6 outputs mentioned above.
SEVEN PROMINENT TYPES OF WASTE TO BE ELIMINATED:
Waste from Overproduction Transportation Waste Processing Waste Waste from Product Defects Waste of waiting/idle time Inventory Waste Waste of Motion
IMPLEMENTATION OF JIT JIT is to eliminate waste in all its forms. The assumption of JIT is that we cannot sell
everything we make. Thus, we must produce salable goods.
Operation = Motion (Waste) + Work (Added Value) Motion alone is a waste that adds cost (counting
things, moving boxes, transporting goods etc) Inventory decouples individual operations and
thereby creates waste to buffer the operations against the effect of a different forms of waste.
For real improvement, we must ask "why" ,when we encounter any form of waste.
IMPLEMENTATION CNTD…
5S’S FOR WORKPLACE IMPROVEMENT
Proper arrangement (sort through and sort out, identify what you need, discard what you do not need )
Orderliness (assign a separate location for all essential items)
Cleanliness (keep the workplace spotless at all times)
Cleanup (maintain equipment and tools) Discipline (stick to the rules scrupulously)
CNTD…
Place the machines in process sequence Design a cellular (U-shaped) layout Make one piece at a time in the cell Cross-train workers to handle multiple processes Produce according to the cycle time Have the operators work standing up and walking Use slower, dedicated machines that are smaller and
less expensive
.
AWARENESS REVOLUTION
1. Abolish old tradition concepts. 2. Assume that new method will work. 3. No excuses are accepted. 4. It is not seeking for perfection, absolutely zero-defect
process, few defects is acceptable. 5. Correct mistakes immediately. 6. Do not spend money on improvement. 7. Use you brain to solve problem. 8. Repeat to ask yourself 5 times before any decision. 9. Gather information from several people, more is better! 10. Remember that improvement has no limits.
FLOW MANUFACTURING
Arrange machines in sequence. U-shaped production line (Cellular
Manufacturing). Produce one-piece at a time. Train workers to be multi-skilled. Follow the cycle time. Let the workers standing and walking
around while working. Use small and dedicated machines.
Standard Operation
Cycle timeWork sequenceStandard stock-on-handUse operation charts
Multi-process handling
Multi-process handling –A worker should handle several different processes at once, this is also
called "vertical handling" and this is the basis for JIT production
REQUIREMENTS FOR A PROPER JIT MANAGEMENT
STANDARDIZATION: Where the supplies are standardized and the suppliers are trustable and close to the plant.
SOFTWARE:For JIT to work efficiently Supply Chain Planning software, companies have in the mean time extended Just-in-time manufacturing externally, by demanding from their suppliers to deliver inventory to the factory only when it's needed.
MULTI-FUNCTIONALITY :In JIT workers & Machines are multifunctional and are required to perform different tasks.
CLEANLINESS :Environment is kept clean and free of waste.
SCHEDULES: Schedules are prepared only for the final assembly line.
QUALITY: Quality within JIT manufacturing is necessary, because without a quality program in JIT, the JIT will fail
THANK YOU