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DefinitionJIT is a manufacturing system whose goal is

to optimize processes and procedure by continuously pursuing waste reduction

It is both a philosophy and a set of methods for manufacturing. Although it has no single, agreed-upon definition ,JIT emphasizes waste reduction, total quality control, and devotion to the customer.

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Evolution of JIT The history of Japan since world war II is

the history of a developing economy, especially manufacturing. The Japanese economy was also ruined and faced the challenge of transition from wartime to a peacetime economy with very resources. This scarcity of resources was a key factor in the evolution of the Just-In-Time philosophy.

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The Seven Wastages Shigeo Shingo, a recognized JIT

authority and engineer at the Toyota Motor Company identifies seven wastes as being the targets of continuous improvement in production process. By attending to these wastes, improvement is achieved.

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Contd…Waste of OverproductionWaste of WaitingWaste of TransportationWaste of Processing itselfWaste of StocksWaste of MotionWaste of Making Defective Products

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Japanese Manufacturing TechniquesProduce what the customer desiresProduce products only at the rate the

customer wants themProduce with perfect qualityProduce by methods that allow people to develop

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• Produce with no waste of labour, material, or equipment; every move has a purpose so there is zero idle inventory • Produce instantaneously – with zero unnecessary lead time

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Minimizing Waste: Group Technology (Part 1)

• Using Departmental Specialization for plant layout can cause a lot of unnecessary material movement

• Using Departmental Specialization for plant layout can cause a lot of unnecessary material movement

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Saw Saw

Lathe PressPress

Grinder

LatheLathe

Saw

Press

Heat Treat

Grinder

Note how the flow lines are going back and forthNote how the flow lines are going back and forth

Minimizing Waste: Group Technology (Part 2)

• Revising by using Group Technology Cells can reduce movement and improve product flow

• Revising by using Group Technology Cells can reduce movement and improve product flow

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Press

Lathe

Grinder

Grinder

A

2

BSaw

Heat Treat

LatheSaw Lathe

PressLathe

1

Minimizing Waste: Just-In-Time

Production

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• Management philosophy• “Pull” system though the plant• Hydraulic Push Systems

WHAT IT IS

• Employee participation• Industrial engineering/basics• Continuing improvement• Total quality control• Small lot sizes

WHAT IT REQUIRES

• Attacks waste• Exposes problems and bottlenecks• Achieves streamlined production

WHAT IT DOES

• Stable environment

WHAT IT ASSUMES

JIT Implementation Requirements: Design Flow ProcessLink operations

Balance workstation capacities

Redesign layout for optimum flow

Emphasize preventive maintenance

Reduce lot sizes

Reduce setup/changeover time

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JIT Implementation Requirements: Total Quality Control

Worker responsibility

SQC in place

Enforce compliance

Fail-safe methods (poka-yoke)

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JIT Implementation Requirements: Work with Vendors

Reduce lead times

Frequent deliveries

Project usage requirements

Clear Quality expectations

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JIT Implementation Requirements: Reduce Inventory MoreLook for other areas to reduced materials

Minimize Stores

Minimize Transit

Carousels

Conveyors

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JIT Implementation Requirements: Improve Product Design

Standard produce configuration

Standardize and reduce number of parts

Align Process design with product design

Quality expectations

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JIT Implementation Requirements: Measure Performance

Emphasize improvement

Track trends

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JIT in Services (Examples)

Organize Problem-Solving Groups

Upgrade Housekeeping

Upgrade Quality

Clarify Process Flows

Revise Equipment and Process Technologies

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JIT in Services (Examples)

Level the Facility Load

Eliminate Unnecessary Activities

Reorganize Physical Configuration

Introduce Demand-Pull Scheduling

Develop Supplier Networks

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