just in time
DESCRIPTION
Introduction to Just in Time, Production and Quality EngineeringTRANSCRIPT
Just-In-Time Manufacturing
JUST-IN-TIMEMANUFACTURING A PowerPoint Presentation BYSWATI(54),MEENAL(39),REENU(45),JAYA(66)
1This PowerPoint presentation focuses on Just-in time manufacturing and its use and implementation in the manufacturing world.
WHAT IS JIT?JIT is a manufacturing philosophy involving an integrated set of procedures/activities designed to achieve a volume of production using minimal inventories.A highly coordinated processing system in which goods move through the system, and services are performed, just as they need.
HOW IT WORKS?
HISTORYEvolved in Japan after World War II, as a result of their diminishing market share in the auto industry.Founded by Taiichi Ohno, a vice president of Toyota.Basically implemented in Toyota plant 1950, well established after 1970.
FOLLOWERSAdopted by General Electrical in the USA in the 1980.Some companies referred JIT with different names:TOYOTA Toyota SystemIBM Continuous flow manufacturingGE- Management by sightHEWLETT- PACKARD- stockless production & repetitive manufacturing system
7 WASTESWaste of over productionWaste of waitingWaste of transportationWaste of Underutilization of EmployeesWaste of InventoryWaste of motionWaste of making defective products
PRINCIPLES OF JIT PRODUCTION
TOTAL QUALITY MANAGEMENTSeek long-term commitment
Quality must be a higher priority than cost
Minimize Waste
PRODUCTION MANAGEMENTPull System vs. Push SystemPull = Made to orderPush = Made for inventory
Communication TechniquesCompletion of task-Kanban Problem- Andon or siren/light
Flexibility of the system
Design For Testability Poka-Yoke= Mistake-proofing
SUPPLIER MANAGEMENTEstablish Long Term Relationships with few suppliers.
Delivery of Parts = 100% Defect FreeWhere they are neededWhen they are neededThe exact quantity
Work Together
Elimination of inspection of parts
E.g. Toyota Productions
Material quality problemsLong setupsPoor trainingBreak downs
Material handling
Traditional systems use inventory (water) to buffer the process from problems (rocks) that cause disruption. Water = InventoryINVENTORY MANAGEMENTEliminate Safety Stock = Zero InventoryInventory is Evil
Material quality problemsLong setupsPoor trainingBreak downs
Material handling
JIT systems view inventory as waste and work to lower inventory levels to expose and correct the problems (rocks) that cause disruption.
Material quality problemsLong setupsPoor trainingBreak downsMaterial handlingLowering the level of inventory is relatively easy to do. However, the problems that arise must be corrected quickly Otherwise, the process will flounder.
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HUMAN RESOURCE MANAGEMENT
Company-wide InvolvementMotivation for continuous improvementProblem Solving
Diversified Employees
Management Support and Empowerment of workforce
JIT MANUFACTURING BUILDING BLOCKS
Product DesignProcessDesignPersonnelElementsManufactur-ing Planning
Eliminate disruptionsMake the system flexibleReduce setupand lead timesEliminate wasteMinimize inventories
Abalancedrapid flowUltimateGoalSupportingGoals
REQUIREMENTS OF JITRespond to Customer RequirementsIntegrate all ProcessesEmployee ParticipationCompany wide Commitment to educationEliminate redundancyReduce all InventoryEstablish Continuous Improvement Goals
Use a pull Production SystemDesign products for ManufacturingDevelop Controllable Production ProcessesHave Defect Prevention ProgramReduce Setup TimesBuild Products to Specification
OBSTACLES IN CONVERSION
Management not committedWorkers not cooperativeDecide which parts need most effortStart by trying to reduce setup timesGradually convert operationsConvert suppliers to JITPrepare for obstaclesSuppliers may resist
ADVANTAGES OF JIT
High qualityFlexibility Reduced setup timesReduced need for indirect laborLess wasteLow warehouse costSynchronization between production scheduling and work hour
DISADVANTAGES OF JIT
Time consuming
No spare product to meet un expected order
Supply Shock : If products do not reach on time
High risk factor
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JIT IN GOODS :Leveraged JIT principles to make its manufacturing process a success
Leverage their suppliers to achieve the JIT goal
Provide exceptionally short set up times to their customers
Suppliers carry inventory instead of carrying it themselves.
Has dependable suppliers with the ability to meet its demanding lead time requirements.
Seamless system that allows it to transmit its component on requirements
Willingness of suppliers to keep inventory on hand.
JIT IN SERVICES: MAC D
McDonalds is the best example of JIT in Services !
McDonald's doesn't begin to cook until a customer has placed a specific order.
The major benefits are better food at a lower cost.
Wastage is reduced along with an improvised taste that makes you want to scream out Im Lovin It !
THANK YOU!!