just-in-time manufacturing? just-in-time manufacturing? b what is jit manufacturing? b where did it...
TRANSCRIPT
Just-In-Time Manufacturing?Just-In-Time Manufacturing?
What is JIT Manufacturing?What is JIT Manufacturing?
Where did it come from?Where did it come from?
What are the main principles?What are the main principles?
Is it easy to Implement?Is it easy to Implement?
What phrase best describes JIT?What phrase best describes JIT?
Just-In Time ManufacturingJust-In Time Manufacturing
JITJIT- A philosophy of - A philosophy of continuous improvementcontinuous improvement that that puts emphasis on prevention rather than correction, puts emphasis on prevention rather than correction, and demands a company wide focus on quality.and demands a company wide focus on quality.
JITJIT- operational management approach to achieve - operational management approach to achieve world class manufacturing. world class manufacturing.
JITJIT- production is based on demand- production is based on demand
History of JIT ManufacturingHistory of JIT Manufacturing
Evolved in Japan after World War II, as a result of their Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. diminishing market share in the auto industry.
Toyota Motor CompanyToyota Motor Company- Birthplace of the JIT Philosophy - Birthplace of the JIT Philosophy Under Taiichi Ohno.Under Taiichi Ohno.• W. Edwards DemingW. Edwards Deming• 14 points for Management14 points for Management
JIT is now on the rise in American Industries.JIT is now on the rise in American Industries.
Principles Of JIT ManufacturingPrinciples Of JIT Manufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Principles Of JIT ManufacturingPrinciples Of JIT Manufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Total Quality ManagementTotal Quality Management
Seek long-term commitment to quality efforts Seek long-term commitment to quality efforts with continuous improvement with continuous improvement
Quality must be a higher priority than costQuality must be a higher priority than cost
Minimizing wasteMinimizing waste
Total Quality ManagementTotal Quality Management
Eliminate Quality InspectorsEliminate Quality Inspectors
Quality is everyone’s responsibilityQuality is everyone’s responsibility
Do it right the first timeDo it right the first time
Principles Of JIT ManufacturingPrinciples Of JIT Manufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Production ManagementProduction Management
Pull System vs. Push SystemPull System vs. Push System• Pull = Made to orderPull = Made to order• Push = Made for inventoryPush = Made for inventory
Flexability of the systemFlexability of the system
Design For Testability – In the processDesign For Testability – In the process• Poka-Yoke= Mistake-proofingPoka-Yoke= Mistake-proofing• Throughout entire processThroughout entire process
Production ManagementProduction Management
Reduced lot sizes= Shorter cycle timesReduced lot sizes= Shorter cycle times
Eliminate disruptions in the processEliminate disruptions in the process
Standardized Parts/ SimplicityStandardized Parts/ Simplicity
Production ManagementProduction Management
Communication TechniquesCommunication Techniques• Completion of taskCompletion of task-Kanban -Kanban • ProblemProblem- Andon or siren/light- Andon or siren/light
Stopping the process if something goes wrong Stopping the process if something goes wrong =Jidoka=Jidoka
Preventive MaintenancePreventive Maintenance
Production Management at Production Management at ToyotaToyota
Toyota uses a Kanban pull system throughout Toyota uses a Kanban pull system throughout the production process.the production process.
Each task in the process seems to take Each task in the process seems to take identical length and work content, so everyone identical length and work content, so everyone is working at the same pace to reduce is working at the same pace to reduce bottlenecks.bottlenecks.
Principles Of JIT ManufacturingPrinciples Of JIT Manufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Supplier ManagementSupplier Management
Establish Long Term Relationships with few suppliers.Establish Long Term Relationships with few suppliers.
Delivery of Parts = 100% Defect FreeDelivery of Parts = 100% Defect Free• Where they are neededWhere they are needed• When they are neededWhen they are needed• The exact quantity The exact quantity
Work TogetherWork Together
Supplier ManagementSupplier Management
Elimination inspection of parts Elimination inspection of parts
Information SystemsInformation Systems• Eliminating barriers to information Eliminating barriers to information
Communicate problems to suppliers in a Communicate problems to suppliers in a positive manner. positive manner.
Supplier Relations at ToyotaSupplier Relations at Toyota
Toyota communicates their damand for parts Toyota communicates their damand for parts 20 days in advance to their suppliers, with the 20 days in advance to their suppliers, with the right to change the forecast up to the 10right to change the forecast up to the 10thth day. day.
Principles Of JIT ManufacturingPrinciples Of JIT Manufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Inventory ManagementInventory Management
Eliminate Safety Stock = Zero InventoryEliminate Safety Stock = Zero Inventory
Reduce WIPReduce WIP
JIT is not an inventory control systemJIT is not an inventory control system
Reduction in inventory opens up spaceReduction in inventory opens up space
Inventory hides problems in a process.Inventory hides problems in a process.
Water Level = InventoryWater Level = Inventory
Rocks = Problems in the systemRocks = Problems in the system
Boat = Company OperationsBoat = Company Operations
Principles Of JIT ManufacturingPrinciples Of JIT Manufacturing
Total Quality ManagementTotal Quality Management
Production ManagementProduction Management
Supplier ManagementSupplier Management
Inventory ManagementInventory Management
Human Resource ManagementHuman Resource Management
Human Resource ManagementHuman Resource Management
Company-wide InvolvementCompany-wide Involvement• Motivation for continuous improvementMotivation for continuous improvement• Problem SolvingProblem Solving• High Employee InteractionHigh Employee Interaction
Build Pride In WorkmanshipBuild Pride In Workmanship
Human Resource ManagementHuman Resource Management
Self-Inspection of workSelf-Inspection of work
Diversified EmployeesDiversified Employees• AbsenteeismAbsenteeism• To eliminate boredom in processTo eliminate boredom in process
Management Support and Empowerment of workforceManagement Support and Empowerment of workforce
Human Resource Management Human Resource Management at Toyotaat Toyota
In 1986 from a labor force of 60,000 Toyota In 1986 from a labor force of 60,000 Toyota received 2.6 million improvement proposals, received 2.6 million improvement proposals, 96% of which were implemented by either 96% of which were implemented by either management or the employees themselves. management or the employees themselves.
WIP Example WIP Example
Implementation ProblemsImplementation Problems
Worker resistanceWorker resistance
Lack of top management supportLack of top management support
Lack of communicationLack of communication
Lack of formal trainingLack of formal training
Most Important QuestionMost Important Question
What phrase best describes the Just-What phrase best describes the Just-In-Time philosophy?In-Time philosophy?
Continuous ImprovementContinuous Improvement
SummarySummary
JITJIT- A philosophy of - A philosophy of continuous improvementcontinuous improvement that puts emphasis on prevention rather than that puts emphasis on prevention rather than correction, and demands a company wide correction, and demands a company wide focus on quality.focus on quality.
ReferencesReferences
Cammaranano, J. Cammaranano, J. Lessons to be Learned: JIT.Lessons to be Learned: JIT. Atlanta, Georgia: Engineering and Management Atlanta, Georgia: Engineering and Management Press, 1997.Press, 1997.
Dear, A. Dear, A. Working toward JIT: Management Technology.Working toward JIT: Management Technology. London: Derek Doyle and Associates, London: Derek Doyle and Associates, 1988.1988.
Fisher, D. Fisher, D. The JIT Self Test: Success Through Assesment and Implementation.The JIT Self Test: Success Through Assesment and Implementation. Chicago, IL: Irwin Chicago, IL: Irwin Inc., 1995. Inc., 1995.
Hernandez, A. Hernandez, A. JIT Quality: A Practical Approach.JIT Quality: A Practical Approach. Englewood Cliffs, NJ: Prentice-Hall, 1993. Englewood Cliffs, NJ: Prentice-Hall, 1993.Hutchins, D. Hutchins, D. Just-In-Time: Inventory Control.Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988. Brookfield, VT: Gower Publishing, 1988.O’Grady, P.J. O’Grady, P.J. Putting the JIT Philosophy Into Practice.Putting the JIT Philosophy Into Practice. New York, NY: Nichols Publishing, 1988. New York, NY: Nichols Publishing, 1988.Reinfeld, N.V. Reinfeld, N.V. Handbook of Production and Inventory Control.Handbook of Production and Inventory Control. Englewood Cliffs, NJ: Prentice-Hall, Englewood Cliffs, NJ: Prentice-Hall,
1987.1987.Schneiderjans, M.J. Schneiderjans, M.J. Advanced Topics In JIT Management: JIT Systems.Advanced Topics In JIT Management: JIT Systems. Westport, CT: Greenwood Westport, CT: Greenwood
Publishing Group, 1999.Publishing Group, 1999.Taver, R.W. Taver, R.W. Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Problem Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Problem
Solving ProcessSolving Process. New York, NY: AMACON, 1995.. New York, NY: AMACON, 1995.Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Winning with Quality: Applying Quality Principles in Winning with Quality: Applying Quality Principles in
Product Development. Product Development. Reading, MASS: Addison-Wesley Publishing Co., 1995.Reading, MASS: Addison-Wesley Publishing Co., 1995.