Just in-timeby stevespangler[1]
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Just-In-TimeJust-In-TimeManufacturing Manufacturing
SARATH PRAKASH.VSARATH PRAKASH.V
MECHANICAL MECHANICAL
G.P.T.C KALAMASSERYG.P.T.C KALAMASSERY
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A Brief OverviewA Brief Overview
• Central ThemesCentral Themes• Prerequisites for ImplementationPrerequisites for Implementation• Just-In-Time TechniquesJust-In-Time Techniques• A Brainstorming ExerciseA Brainstorming Exercise• A Competitive EdgeA Competitive Edge• Major Misconceptions of JITMajor Misconceptions of JIT
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A Brief Overview A Brief Overview (cont’d.)(cont’d.)
• Goals of Just-In-Time ManufacturingGoals of Just-In-Time Manufacturing• Advantages of Just-In-Time Advantages of Just-In-Time
ManufacturingManufacturing• How JIT WorksHow JIT Works• A Real World ExampleA Real World Example• An ExerciseAn Exercise• SummarySummary
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Just-In-Time Manufacturing:Just-In-Time Manufacturing:A DefinitionA Definition
• Uses a systems approach to develop and Uses a systems approach to develop and operate a manufacturing systemoperate a manufacturing system
• Organizes the production process so Organizes the production process so that parts are available when they are that parts are available when they are neededneeded
• A method for optimizing processes that A method for optimizing processes that involves continual reduction of wasteinvolves continual reduction of waste
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Central Themes SurroundingCentral Themes SurroundingJust-In-TimeJust-In-Time
• SimplicitySimplicity
• QualityQuality
• Elimination of WasteElimination of Waste
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Prerequisites for JITPrerequisites for JITImplementationImplementation
• A Reason for ChangingA Reason for Changing• Executive CommitmentExecutive Commitment• Strategic Manufacturing PlanStrategic Manufacturing Plan• Commitment to ActionCommitment to Action
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Just-In-TimeJust-In-TimeTechniquesTechniques
• Inventory Reduction as a Tool for Inventory Reduction as a Tool for ImprovementImprovement
• Supplier RelationshipsSupplier Relationships• Inventory “Pull”Inventory “Pull”• Uniform Plant LoadingUniform Plant Loading
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Just-In-TimeJust-In-TimeTechniquesTechniques(cont’d)(cont’d)
• Reduced Setup TimesReduced Setup Times• Shop-Floor Layout and Production Shop-Floor Layout and Production
CellsCells• Total Quality AssuranceTotal Quality Assurance• Preventive MaintenancePreventive Maintenance
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Brainstorming Exercise:Brainstorming Exercise:
• How can Just-In-Time How can Just-In-Time Manufacturing be Effective in your Manufacturing be Effective in your Business?Business?
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A Competitive EdgeA Competitive Edge
• Integrating and OptimizingIntegrating and Optimizing
• Improve ContinuouslyImprove Continuously
• Understanding the CustomerUnderstanding the Customer
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The Major Misconceptions The Major Misconceptions of JITof JIT
• JIT is Only an Inventory Control JIT is Only an Inventory Control SystemSystem
• It is a Method to “Push” Inventory It is a Method to “Push” Inventory Back to the SupplierBack to the Supplier
• JIT is a Quality Control ProgramJIT is a Quality Control Program
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Goals of Just-In-Time Goals of Just-In-Time SystemsSystems
• Design for Optimum Quality and Design for Optimum Quality and CostCost
• Minimize resources needed for Minimize resources needed for Design and ManufacturingDesign and Manufacturing
• Be Responsive to the Customers Be Responsive to the Customers NeedsNeeds
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Goals of Just-In-TimeGoals of Just-In-TimeSystemsSystems(cont’d)(cont’d)
• Develop Trust and Open Develop Trust and Open Relationships with Suppliers and Relationships with Suppliers and CustomersCustomers
• Develop a Commitment to Improve Develop a Commitment to Improve the Total Manufacturing Systemthe Total Manufacturing System
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Advantages of JIT Advantages of JIT ManufacturingManufacturing
• Materials Cost SavingsMaterials Cost Savings
• Manufacturing Cost SavingsManufacturing Cost Savings
• Sales Cost SavingsSales Cost Savings
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Elements in Materials Cost Elements in Materials Cost SavingSaving
• Reduction of Reduction of SuppliersSuppliers
• Long-term Long-term ContractsContracts
• Reduce Order Reduce Order SchedulingScheduling
• Simplify Receiving Simplify Receiving SystemsSystems
• Eliminate Eliminate unpackingunpacking
• Eliminate Eliminate InspectionInspection
• Eliminate Eliminate inventory inventory StockingStocking
• Eliminate Excess Eliminate Excess MaterialMaterial
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How Just-In-Time Systems How Just-In-Time Systems WorkWork
• Requirements for JIT ManufacturingRequirements for JIT Manufacturing
• Firm-wide CommitmentFirm-wide Commitment
• Knowledgeable ManagementKnowledgeable Management
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Requirements for JITRequirements for JIT
• Respond to Customer Respond to Customer RequirementsRequirements
• Integrate all Integrate all Processes in the Processes in the Manufacturing Manufacturing SystemSystem
• Employee Employee Participation in Participation in Meeting Meeting CommitmentsCommitments
• Company wide Company wide Commitment to Commitment to educationeducation
• Eliminate Eliminate redundancyredundancy
• Reduce all InventoryReduce all Inventory• Establish Continuous Establish Continuous
Improvement GoalsImprovement Goals
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Requirements for JITRequirements for JIT(cont’d)(cont’d)
• Use a pull Use a pull Production Production SystemSystem
• Design products Design products for Manufacturingfor Manufacturing
• Develop Develop Controllable Controllable Production Production ProcessesProcesses
• Have a Defect Have a Defect Prevention Prevention ProgramProgram
• Reduce Setup Reduce Setup TimesTimes
• Build Products to Build Products to SpecificationSpecification
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A Real World ExampleA Real World Example
• The Toyota Production SystemThe Toyota Production System
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A JIT ExerciseA JIT Exercise
• Q: What are the three central Q: What are the three central themes surrounding Just-In-Time themes surrounding Just-In-Time Manufacturing and why are they Manufacturing and why are they important?important?
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SummarySummary
• A review of Just-In-Time A review of Just-In-Time Manufacturing SystemsManufacturing Systems
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BibliographyBibliography
• Mito, Setsuo and Ohno, Taiichi.Mito, Setsuo and Ohno, Taiichi. Just-In-TimeJust-In-Time For For
Today And Tomorrow. Today And Tomorrow. Cambridge:Cambridge: Productivity Productivity Press, Inc., 1986.Press, Inc., 1986.
• Lubben, Richard T.. Lubben, Richard T.. Just-In-Time Just-In-Time Manufacturing. Manufacturing. New York: McGraw-Hill Book New York: McGraw-Hill Book Co., 1988.Co., 1988.
• Maskell, Brian H.. Maskell, Brian H.. Just In Time. Just In Time. Carol Stream: Carol Stream: Hitchcock Publishing Co., 1989.Hitchcock Publishing Co., 1989.