Just-In-Time Manufacturing

JUST-IN-TIMEMANUFACTURING A PowerPoint Presentation BYSWATI(54),MEENAL(39),REENU(45),JAYA(66)

1This PowerPoint presentation focuses on Just-in time manufacturing and its use and implementation in the manufacturing world.

WHAT IS JIT?JIT is a manufacturing philosophy involving an integrated set of procedures/activities designed to achieve a volume of production using minimal inventories.A highly coordinated processing system in which goods move through the system, and services are performed, just as they need.

HOW IT WORKS?

HISTORYEvolved in Japan after World War II, as a result of their diminishing market share in the auto industry.Founded by Taiichi Ohno, a vice president of Toyota.Basically implemented in Toyota plant 1950, well established after 1970.

FOLLOWERSAdopted by General Electrical in the USA in the 1980.Some companies referred JIT with different names:TOYOTA Toyota SystemIBM Continuous flow manufacturingGE- Management by sightHEWLETT- PACKARD- stockless production & repetitive manufacturing system

7 WASTESWaste of over productionWaste of waitingWaste of transportationWaste of Underutilization of EmployeesWaste of InventoryWaste of motionWaste of making defective products

PRINCIPLES OF JIT PRODUCTION

TOTAL QUALITY MANAGEMENTSeek long-term commitment

Quality must be a higher priority than cost

Minimize Waste

PRODUCTION MANAGEMENTPull System vs. Push SystemPull = Made to orderPush = Made for inventory

Communication TechniquesCompletion of task-Kanban Problem- Andon or siren/light

Flexibility of the system

Design For Testability Poka-Yoke= Mistake-proofing

SUPPLIER MANAGEMENTEstablish Long Term Relationships with few suppliers.

Delivery of Parts = 100% Defect FreeWhere they are neededWhen they are neededThe exact quantity

Work Together

Elimination of inspection of parts

E.g. Toyota Productions

Material quality problemsLong setupsPoor trainingBreak downs

Material handling

Traditional systems use inventory (water) to buffer the process from problems (rocks) that cause disruption. Water = InventoryINVENTORY MANAGEMENTEliminate Safety Stock = Zero InventoryInventory is Evil

Material quality problemsLong setupsPoor trainingBreak downs

Material handling

JIT systems view inventory as waste and work to lower inventory levels to expose and correct the problems (rocks) that cause disruption.

Material quality problemsLong setupsPoor trainingBreak downsMaterial handlingLowering the level of inventory is relatively easy to do. However, the problems that arise must be corrected quickly Otherwise, the process will flounder.

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HUMAN RESOURCE MANAGEMENT

Company-wide InvolvementMotivation for continuous improvementProblem Solving

Diversified Employees

Management Support and Empowerment of workforce

JIT MANUFACTURING BUILDING BLOCKS

Product DesignProcessDesignPersonnelElementsManufactur-ing Planning

Eliminate disruptionsMake the system flexibleReduce setupand lead timesEliminate wasteMinimize inventories

Abalancedrapid flowUltimateGoalSupportingGoals

REQUIREMENTS OF JITRespond to Customer RequirementsIntegrate all ProcessesEmployee ParticipationCompany wide Commitment to educationEliminate redundancyReduce all InventoryEstablish Continuous Improvement Goals

Use a pull Production SystemDesign products for ManufacturingDevelop Controllable Production ProcessesHave Defect Prevention ProgramReduce Setup TimesBuild Products to Specification

OBSTACLES IN CONVERSION

Management not committedWorkers not cooperativeDecide which parts need most effortStart by trying to reduce setup timesGradually convert operationsConvert suppliers to JITPrepare for obstaclesSuppliers may resist

ADVANTAGES OF JIT

High qualityFlexibility Reduced setup timesReduced need for indirect laborLess wasteLow warehouse costSynchronization between production scheduling and work hour

DISADVANTAGES OF JIT

Time consuming

No spare product to meet un expected order

Supply Shock : If products do not reach on time

High risk factor

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JIT IN GOODS :Leveraged JIT principles to make its manufacturing process a success

Leverage their suppliers to achieve the JIT goal

Provide exceptionally short set up times to their customers

Suppliers carry inventory instead of carrying it themselves.

Has dependable suppliers with the ability to meet its demanding lead time requirements.

Seamless system that allows it to transmit its component on requirements

Willingness of suppliers to keep inventory on hand.

JIT IN SERVICES: MAC D

McDonalds is the best example of JIT in Services !

McDonald's doesn't begin to cook until a customer has placed a specific order.

The major benefits are better food at a lower cost.

Wastage is reduced along with an improvised taste that makes you want to scream out Im Lovin It !

THANK YOU!!