Just-InJust-In-Time Manufacturing

Matt Schmidt Penn State University OISM 470W

Just-InJust-In-Time Manufacturing?
What is JIT Manufacturing? Where did it come from? What are the main principles? Is it easy to Implement? What phrase best describes JIT?

JustJust-In Time Manufacturing

JITJIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality. JITJIT- operational management approach to achieve world class manufacturing. JITJIT- production is based on demand

History of JIT Manufacturing

Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. Toyota Motor Company- Birthplace of the JIT CompanyPhilosophy Under Taiichi Ohno.
W. Edwards Deming 14 points for Management

JIT is now on the rise in American Industries.

Principles Of JIT Manufacturing

Total Quality Management Production Management Supplier Management Inventory Management Human Resource Management

Principles Of JIT Manufacturing

Total Quality Management
Production Management Supplier Management Inventory Management Human Resource Management

Total Quality Management

Seek long-term commitment to quality longefforts with continuous improvement Quality must be a higher priority than cost Minimizing waste

Total Quality Management

Eliminate Quality Inspectors Quality is everyones responsibility Do it right the first time

Principles Of JIT Manufacturing

Total Quality Management

Production Management
Supplier Management Inventory Management Human Resource Management

Production Management
Pull System vs. Push System
Pull = Made to order Push = Made for inventory

Flexability of the system Design For Testability In the process

Poka-Yoke= Mistake-proofing PokaMistake Throughout entire process

Production Management
Reduced lot sizes= Shorter cycle times Eliminate disruptions in the process Standardized Parts/ Simplicity

Production Management
Communication Techniques
Completion of task-Kanban task Problem- Andon or siren/light Problem-

Stopping the process if something goes wrong =Jidoka Preventive Maintenance

Production Management at Toyota



Toyota uses a Kanban pull system throughout the production process. Each task in the process seems to take identical length and work content, so everyone is working at the same pace to reduce bottlenecks.

Principles Of JIT Manufacturing

Total Quality Management Production Management

Supplier Management
Inventory Management Human Resource Management

Supplier Management
Establish Long Term Relationships with few suppliers. Delivery of Parts = 100% Defect Free
Where they are needed When they are needed The exact quantity

Work Together

Supplier Management
Elimination inspection of parts Information Systems
Eliminating barriers to information

Communicate problems to suppliers in a positive manner.

Supplier Relations at Toyota



Toyota communicates their damand for parts 20 days in advance to their suppliers, with the right to change the forecast up to the 10th day.

Principles Of JIT Manufacturing

Total Quality Management Production Management Supplier Management

Inventory Management
Human Resource Management

Inventory Management
Eliminate Safety Stock = Zero Inventory Reduce WIP JIT is not an inventory control system Reduction in inventory opens up space

Inventory hides problems in a process. Water Level = Inventory Rocks = Problems in the system Boat = Company Operations

Principles Of JIT Manufacturing

Total Quality Management Production Management Supplier Management Inventory Management

Human Resource Management

Human Resource Management

CompanyCompany-wide Involvement
Motivation for continuous improvement Problem Solving High Employee Interaction

Build Pride In Workmanship

Human Resource Management

SelfSelf-Inspection of work Diversified Employees
Absenteeism To eliminate boredom in process

Management Support and Empowerment of workforce

Human Resource Management at Toyota

In 1986 from a labor force of 60,000 Toyota received 2.6 million improvement proposals, 96% of which were implemented by either management or the employees themselves.

WIP Example

Implementation Problems
Worker resistance Lack of top management support Lack of communication Lack of formal training

Most Important Question

What phrase best describes the Just-InJust-In-Time philosophy?

Continuous Improvement

Summary
JITJIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality.

References

Cammaranano, J. Lessons to be Learned: JIT. Atlanta, Georgia: Engineering and Management Press, 1997. Dear, A. Working toward JIT: Management Technology. London: Derek Doyle and Associates, 1988. Fisher, D. The JIT Self Test: Success Through Assesment and Implementation. Chicago, IL: Irwin Inc., 1995. Hernandez, A. JIT Quality: A Practical Approach. Englewood Cliffs, NJ: Prentice-Hall, 1993. PrenticeHutchins, D. Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988. Just-InOGrady, P.J. Putting the JIT Philosophy Into Practice. New York, NY: Nichols Publishing, 1988. Reinfeld, N.V. Handbook of Production and Inventory Control. Englewood Cliffs, NJ: PrenticePrenticeHall, 1987. Schneiderjans, M.J. Advanced Topics In JIT Management: JIT Systems. Westport, CT: Greenwood Publishing Group, 1999. Taver, R.W. Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Problem Solving Process. New York, NY: AMACON, 1995. Process. Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Winning with Quality: Applying Quality Principles in Product Development. Reading, MASS: Addison-Wesley Publishing Co., 1995. Addison-