Just-in-Time and Just-in-Time and Lean Systems Lean Systems

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The Philosophy of JIT Often termed “Lean Systems” All waste must be eliminated- non value items Broad view that entire organization must focus

on serving customers JIT is built on simplicity- the simpler the better Focuses on improving every operation- Kaizen Install simple visible control systems Flexibility to produce different models/features

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A Simple Definition of JIT

A philosophy of manufacturing based on planned elimination of ALL waste,

and improvement of productivity and customer value,

through “Continuous Improvement” (or ‘Kaizen’) ……

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Waste is ‘anything other than the minimum amount of equipment, materials, parts, space, and worker’s time, which are absolutely essential to add value to the product.’

— Shoichiro Toyoda President, Toyota © 1995 Corel Corp.

a. What is ‘Waste’?

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THE SEVEN WASTES

Waste of over productionWaste of over production Waste of waiting Waste of waiting Waste of transportation Waste of transportation    Waste of processing itself Waste of processing itself Waste of stocks Waste of stocks Waste of motionWaste of motion Waste of making defective Waste of making defective

productsproducts

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The Problem of Manufacturing…

Getting the right material and physical resources together at the right place and at the right time to meet the customer’s requirements.

Desired features, On time delivery, High Quality, at the best price…

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Breaking down the problem… Getting the

material needed… Having enough

inventory of material to support production

Not having too much inventory and extra costs…

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Claims for JIT: reduced inventoryreduced inventory

shorter lead timesshorter lead times not too early, not to late...not too early, not to late...

   JIT is the result businesses want, JIT is the result businesses want,

not a starting pointnot a starting point  

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A More Complete Definition of JIT

JIT (Just-In-Time)is

a STATE OF MINDfor

achieving competitive excellenceby

creating an attitude of continuous improvement,

through 100 percent involvementto

eliminate all waste,institutionalizing only value-adding

activitieswith

100 percent quality—NOTHING LESS

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Three Elements of JIT

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Elements of JIT Manufacturing

Inventory reduction exposes problems

Kanbans & pull production systems Small lots & quick setups Uniform plant loading Flexible resources Efficient facility layouts

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Role of Inventory Reduction Inventory = Lead Time (less is better) Inventory hides problems

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Small Lot Sizes & Quick Setups

Small lots mean less average inventory and shorten manufacturing lead time

Small lots with shorter setup times increase flexibility to respond to demand changes

Strive for single digit setups- < 10 minutes

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Effective Facility Layouts Workstations in close physical proximity

to reduce transport & movement Streamlined flow of material Often use:

Cellular Manufacturing (instead of process focus)

U-shaped lines: (allows material handler to quickly drop off materials & pick up finished work)

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Types of Manufacturing Layout

Process Layout Product Layout Cellular Layout

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Traditional Process Focused Layout

Jumbled flows, long cycles, difficult to schedule

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Process Layout Characteristics Advantages

Deep knowledge of the process Common tooling and fixtures Most Flexible -- can produce many different

part types Disadvantages

Spaghetti flow -- everything gets all tangled up (can not “pull” materials with this layout)

Lots of in-process materials Hard to control inter-department activities Can be difficult to automate

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PRODUCT LAYOUT

Shipping

L L M D

L M D

G

L M GG

A A

Receiving

Part #1

Part #3

Part #2

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Product Layout Characteristics Advantages

Easy to control -- input control Minimum material handling -- frequently

linked to the next process Minimal in-process materials Can be more easily automated

Disadvantages Inflexible -- can only produce one or two parts Large setup Duplicate tooling is required for all cells

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JIT Cellular Manufacturing Product focused cells, flexible equipment,

high visibility, easy to schedule, short cycles

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Cellular Layout Characteristics Advantages

Control is simplified Common tooling and fixtures Flexible -- can produce many different part

types - a part family?? Disadvantages

Setup ?? Need to know about many different

processes

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Process Layout Work Cell

SawSaw

LatheLathe

GrinderGrinder

HeatHeatTreatTreat

LatheLathe

Lathe

Lathe SawSaw

HeatHeatTreatTreat

GrinderGrinder

GrinderGrinder

PressPress

PressPress 1

1

2

3

45

2

6

SawSaw

PressPress

From Process Layout to Work Cell – For Flow

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Benefits of JIT

Smaller inventories Shorter lead times Improved quality Reduced space requirements Lower production costs Increased productivity Greater flexibility

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Quality Processes Yield Quality Results

ConsistentProcess

DesiredResults

InconsistentProcess

InconsistentResults

Traditional = People doing whatever they can to get results

Lean = People using standard process to get results

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Definition of

Lean Manufacturing“A philosophy of production that emphasizes the minimization of the amount of all the resources (including time) used in the various activities of the enterprise. It involves:

… identifying and eliminating non-value-adding activities,

… employing teams of multi-skilled workers, … using highly flexible equipment, which

may eventually be automated.”

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Implementing JIT

Reorganize workplace Remove clutter & minimize storage

Reduce setup times Reduce lot sizes & lead times Implement layout changes

Cellular manufacturing & close proximity Switch to pull production Extend methods to suppliers

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People Make JIT Work JIT has a strong element of training and

involvement of workers. A culture of mutual trust and teamwork

must be developed. An attitude of loyalty to the team and

self-discipline must be developed. Another crucial element of JIT is

empowerment of workers, giving them the authority to solve production problems.

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Highlights JIT manufacturing has become the standard

for many industries; concept incorporates TQM and respect for people.

JIT views waste as anything that does not add value.

JIT converts traditional “push” systems to a “pull” production system.

Key elements of JIT are “pull”, kanbans, small lots, quick setups, uniform plant loading, flexibility, and work cells.

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Highlights (Continued)

TQM concepts must be incorporated JIT manufacturing.

Team based work systems, empowerment, cross-functional flexibility, with appropriate reward systems are all part of JIT.

Most of the JIT concepts are equally applicable to “Service Organizations.”

JIT requires changes to be made in all functional areas and examination of all processes for waste.

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THANK YOU