JUST - IN - TIMEJUST - IN - TIME

A philosophy of production based on A philosophy of production based on

planned elimination of planned elimination of allall waste and waste and

continuous improvement of productivity.continuous improvement of productivity.

JUST - IN - TIME GOALSJUST - IN - TIME GOALS

Zero Defects Zero Defects

Zero Setup TimeZero Setup Time

Zero Lot ExcessesZero Lot Excesses

Zero HandlingZero Handling

Zero SurgingZero Surging

Zero BreakdownsZero Breakdowns

Zero Lead TimeZero Lead Time

JIT IS JIT IS NOTNOT

Business as usualBusiness as usual Doing today as yesterdayDoing today as yesterday A management programA management program A project with a start & finishA project with a start & finish A cost reduction programA cost reduction program A capital investment projectA capital investment project Only for operationsOnly for operations

WASTEWASTE

It can usually be found in:

defectives overproduction waiting transportation processing inventory

INVENTORY WASTEINVENTORY WASTE

Buy EarlyBuy Early

Buy ExtraBuy Extra

Build EarlyBuild Early

Build ExtraBuild Extra

Early CompletionEarly Completion

JUST - IN - TIMEJUST - IN - TIME

Uniform Plant LoadingUniform Plant Loading

Group TechnologyGroup Technology

Quality Control at the SourceQuality Control at the Source

Minimized Setup TimesMinimized Setup Times

Kanban Type PC SystemsKanban Type PC Systems

PRODUCT STRUCTUREPRODUCT STRUCTURE

PRODUCT

C - 1 A - 1 C - 2

C - 3 C - 4

MANUFACTURING CYCLE TIMEMANUFACTURING CYCLE TIME

SETUP TIME - prepare for operationSETUP TIME - prepare for operation

PROCESS TIME - perform operationPROCESS TIME - perform operation

WAIT TIME - after operation endsWAIT TIME - after operation ends

MOVE TIME - move to next operationMOVE TIME - move to next operation

QUEUE TIME -before operations beginsQUEUE TIME -before operations begins

MANUFACTURING CYCLE TIMEMANUFACTURING CYCLE TIME

Setuptime

Processtime

Movetime

Waittime

Queue time

SETUP TIME REDUCTIONSETUP TIME REDUCTION

Eliminate setup timeEliminate setup time

Convert internal to external Convert internal to external

Reduce internalReduce internal

Setup Time

Internal(machine stopped)

External (machine running)

JOB SHOP CONFIGURATIONJOB SHOP CONFIGURATION

M1M1M1M1M1M1M1

M2M2M2M2

M3M3M3M3M3

M4M4M4

M5M5

M6

WC # 1

WC # 2

WC # 3

WC # 4

WC # 5

WC # 6

GROUP TECHNOLOGY CELLGROUP TECHNOLOGY CELL

Family 1(20 parts)

Lathe Press

Grinder

HeatTreat

PaintTo

Assembly

JIT QUALITY DIRECTIONSJIT QUALITY DIRECTIONS

Enhance Quality Assurance

Small Lot Production

Expose QualityProblems

Fast DetectionFast Correction

Further LotSize Reductions

Quality ProblemElimination

Waste Prevention Waste Reduction

Improved JIT PerformanceImproved Quality

JIT ELEMENTSJIT ELEMENTS HousekeepingHousekeeping Quality FocusQuality Focus Flexible ChangeoversFlexible Changeovers Lost Size of OneLost Size of One Balanced FlowBalanced Flow Skill DiversificationSkill Diversification Visibility ControlVisibility Control Preventive MaintenancePreventive Maintenance Compact Plant LayoutCompact Plant Layout Supplier NetworkingSupplier Networking Workforce ParticipationWorkforce Participation Cellular ManufacturingCellular Manufacturing Pull SystemPull System

KANBANS

Production is driven by demand (not capacity),so it balances supply with demand. They

• prevents overproduction• provides production information• provides pickup/transport information• prevents excessive transport• serves as a work order attached to material• detects defects and their source quickly• maintains inventory control

CONTINUAL IMPROVEMENT FRAMEWORKCONTINUAL IMPROVEMENT FRAMEWORK

IdentifyConstraints

OptimizeThroughput

Expand theConstraints

NewConstraints

Emerge

IncreasedMarket Demand

Market

Expansion

INVENTORY REALITIESINVENTORY REALITIES

Consumes capitalConsumes capital

Requires storage spaceRequires storage space

Incurs taxesIncurs taxes

Requires insuranceRequires insurance

Can become lost, stolen, damaged, outdated, or obsoleteCan become lost, stolen, damaged, outdated, or obsolete

Must be counted, sorted, verified, stored, retrieval, Must be counted, sorted, verified, stored, retrieval, moved, issued, and protectedmoved, issued, and protected

CONVENTIONAL VS. JIT ATTITUDESCONVENTIONAL VS. JIT ATTITUDES

CONVENTIONALCONVENTIONALSome defects are acceptableSome defects are acceptableLarge lots are efficient Large lots are efficient (more is better)(more is better)Faster production is efficientFaster production is efficient (the sooner the better)(the sooner the better)Inventory provides safetyInventory provides safetyInventory smoothes productionInventory smoothes productionInventory is an assetInventory is an assetQueues are necessaryQueues are necessarySuppliers are adversariesSuppliers are adversariesMultiple supply sourcesMultiple supply sourcesBreakdown maintenanceBreakdown maintenanceLong lead time is betterLong lead time is betterSetup time is givenSetup time is givenManagement by edictManagement by edict

JUST - IN - TIMEJUST - IN - TIMEZero defects are necessary and attainableZero defects are necessary and attainableIdeal lot size is one Ideal lot size is one (less is better)(less is better)Balanced production is efficient Balanced production is efficient (faster production is a waste)(faster production is a waste)Safety stock is a wasteSafety stock is a wasteInventory is undesirableInventory is undesirableInventory is a liabilityInventory is a liabilityEliminate all queuesEliminate all queuesSuppliers are partnersSuppliers are partnersFewer sources of supplyFewer sources of supplyPreventive maintenancePreventive maintenanceKeep lead time shortKeep lead time shortDrive setup time to zeroDrive setup time to zeroManagement by consensusManagement by consensus

JIT SUGGESTIONSJIT SUGGESTIONS

1. Avoid interrupted work flow1. Avoid interrupted work flow– decrease setup timedecrease setup time– control quality at sourcecontrol quality at source– eliminate machine breakdownseliminate machine breakdowns

2. Eliminate material handling and stocking2. Eliminate material handling and stocking– arrange equipment to product flowarrange equipment to product flow– reduce space between operationsreduce space between operations– eliminate stocking pointseliminate stocking points

3. Synchronize production3. Synchronize production– cross train operatorscross train operators– uniform plant loadinguniform plant loading– schedule only what is neededschedule only what is needed– eliminate queues and bankseliminate queues and banks– frequent vendor deliveryfrequent vendor delivery

4. Pull Scheduling4. Pull Scheduling– only make what is usedonly make what is used

CONTINUAL IMPROVEMENTCONTINUAL IMPROVEMENT

Identify Constraints

Optimize Constraint Output

Subordinate All DecisionsTo Constraint Optimization

Expand the Constraint

IsConstraint

Still Active?YES NO