just in time:by sashi prabhu
TRANSCRIPT
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JustJust--InIn--TimeTime
Eliminate WasteEliminate Waste
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Flexible ResourcesFlexible Resources
Multifunctional workersMultifunctional workers
Operate more than one machine &Operate more than one machine &jobsjobs
GeneralGeneral--purpose machinespurpose machines
Machines that are not highlyMachines that are not highly
specializedspecialized
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Cellular LayoutsCellular Layouts
Manufacturing cellsManufacturing cells
Often UOften U--shaped or linearshaped or linear
Work flows through cell in oneWork flows through cell in onedirection and experiences littledirection and experiences littlewaitingwaiting
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Pull SystemPull System
Coordinating production andCoordinating production anddelivery of materials anddelivery of materials andcomponentscomponents
Traditionally, inventory has beenTraditionally, inventory has beenused as a cushion against lapses inused as a cushion against lapses in
coordination and inventory can becoordination and inventory can behugehuge
Pull system a la at USPull system a la at US
supermarketssupermarkets
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Pull SystemPull System
Do not order more product thanDo not order more product thancan be usedcan be used
(or items that can be sold)(or items that can be sold)
Reversal of normal Reversal of normal pushpush systemsystem
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Kanban Production ControlKanban Production Control
SystemSystem Japanese word for cardJapanese word for card
Associated with fixedAssociated with fixed--qu
antityqu
antityinventory systeminventory system
TwoTwo--bin systembin system KanbanKanban
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SmallSmall--Lot ProductionLot Production
Requires less space and capitalRequires less space and capital
Produces small amounts at a timeProduces small amounts at a time
Processes can be moved closerProcesses can be moved closertogethertogether
Transportation between stations isTransportation between stations is
simplifiedsimplified Quality problems are easier toQuality problems are easier to
detectdetect
Reveals errors and bottlenecksReveals errors and bottlenecks
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Lead TimeLead Time
Processing timeProcessing time
Can be reduced by reducing numberCan be reduced by reducing numberof items processed and the efficiencyof items processed and the efficiencyor speed of the workeror speed of the worker
Move timeMove time
Can be decreased if machines areCan be decreased if machines aremoved closer together, method ofmoved closer together, method ofmovement simplified, routings aremovement simplified, routings arestandardized, or need for movementstandardized, or need for movement
eliminatedeliminated
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Lead TimeLead Time
Waiting TimeWaiting Time
Can be reduced through betterCan be reduced through betterscheduling of materials, workers,scheduling of materials, workers,machines and sufficient capacitymachines and sufficient capacity
Setup TimeSetup Time
Reduction of setup time is importantReduction of setup time is importantto JITto JIT
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Quick SetupsQuick Setups
Streamline all aspects of setupStreamline all aspects of setup
Organize workplace properly locating toolsOrganize workplace properly locating tools
near points ofusenear points ofuse Keep machines and fixtures in good repairKeep machines and fixtures in good repair
Simplify or eliminate adjustmentsSimplify or eliminate adjustments
precoding desired settings, using locator pins,precoding desired settings, using locator pins,
etc.etc. Perform setup activities in parallel orPerform setup activities in parallel or
eliminateeliminate
Add a person, standardize components,Add a person, standardize components,
parts, materialsparts, materials
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Uniform Production LevelsUniform Production Levels
Smoothing productionSmoothing productionrequirements on the final assemblyrequirements on the final assembly
lineline
Better forecastBetter forecast
Mixed production throughout the dayMixed production throughout the day
in small quantities on all productionin small quantities on all productionfacilities.facilities.
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Qualityat the SourceQualityat the Source
For JIT to work, quality has to beFor JIT to work, quality has to behighhigh
No extra inventory to bufferNo extra inventory to bufferagainst defective unitsagainst defective units
Producing poorProducing poor--quality items andquality items and
reworking items or rejecting them isreworking items or rejecting them iswastefulwasteful
Workers are responsible forWorkers are responsible for
inspectioninspection
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Qualityat the SourceQualityat the Source
JidokaJidoka Authority to stop production line ifAuthority to stop production line if
quality problems are encounteredquality problems are encountered AndonsAndons
Call lights activated by switchesCall lights activated by switches
Undercapacity schedulingUndercapacity schedulingMaking time to plan, train, solveMaking time to plan, train, solve
problems, maintain workproblems, maintain workenvironmentenvironment
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Qualityat the SourceQualityat the Source
Visual controlVisual control
Quality improves when problems areQuality improves when problems are
made visible and workers have clearmade visible and workers have clearexpectations of performanceexpectations of performance
Kanbans, andons, process controlKanbans, andons, process control
charts, tool boards, material handlingcharts, tool boards, material handlingroutes clearly marked, demos,routes clearly marked, demos,instructional photos, performanceinstructional photos, performancedatadata
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Qualityat the SourceQualityat the Source
PokaPoka--yokeyoke
Foolproof device or mechanism thatFoolproof device or mechanism that
prevents defects from occurringprevents defects from occurring
KaizenKaizen
Continuous improvementContinuous improvement
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TotalProductive MaintenanceTotalProductive Maintenance
Breakdown maintenanceBreakdown maintenance
Preventive maintenancePreventive maintenance
Total Productive MaintenanceTotal Productive Maintenance Accurate records on time betweenAccurate records on time between
breakdownsbreakdowns
Frequency of breakdownsFrequency of breakdowns
Costs of breakdownsCosts of breakdowns Determine a preventive maintenanceDetermine a preventive maintenance
scheduleschedule
Employee involvementEmployee involvement
Zero defectsZero defects
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Supplier NetworksSupplier Networks
Working with suppliers to improveWorking with suppliers to improveresponsiveness and qualityresponsiveness and quality
Trends:Trends: Locate near the factoryLocate near the factory
Use small, sideUse small, side--loaded trucks and ship mixed loadsloaded trucks and ship mixed loads
Consider establishing small warehouses near to theConsider establishing small warehouses near to thefactory.factory.
Use standardized containers and make deliveriesUse standardized containers and make deliveries
according to a precise delivery scheduleaccording to a precise delivery schedule Become a certified supplier and accept payment atBecome a certified supplier and accept payment at
regular intervals rather than upon deliveryregular intervals rather than upon delivery
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Benefits of JITBenefits of JIT
Reduced inventoryReduced inventory
Improved qualityImproved quality
Lower costsLower costs
Reduced space requirementsReduced space requirements
Shorter lead timeShorter lead time Increased productivityIncreased productivity
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Benefits of JITBenefits of JIT
Greater flexibilityGreater flexibility
Better relations with suppliersBetter relations with suppliers
Simplified scheduling and controlSimplified scheduling and controlactivitiesactivities
Increased capacityIncreased capacity
Better use of human resourcesBetter use of human resources
More product varietyMore product variety