Just in Time ( J. I. T.

Just in Time Philosophy

Salient features

The notion of waste in any operating

system
JIT as a philosophy of elimination of
waste
As a deliberate and a systematic attempt
On a continuous basis

Just In Time Manufacturing

Water Flow Analogy

Unrealistic
schedules
Quality

Lack

Variable
Processing

Defective
Material

Poor

of
Times
training
Machine
Breakdown

Inadequate
Bottleneck
Information
Behavioural/Managerial constraints

JIT Philosophy
Core Logic

Heightened
awareness of
problems & causes

Ideas for
cutting
lot sizes

Lot size
reductions

Less
inventory

Ideas for
improving
JIT delivery

Ideas for
controlling
defects

JIT
Productions

Deliberate withdrawal
of buffer inventories

Reduced buffer
inventories
Fast feedback
on defects

Scrap/quality
control

Less indirect costs

Smoother
output rates

Fewer
rework

Less
material waste

High quality
Finished goods

Less material, labour, indirect costs & better quality

JIT Philosophy
Overall Impact

JIT Manufacturing
Basic Elements

Manufacturing system should conform to a flow

process
Total Quality Management to be deployed
Standard Containers
Constantly eliminate waste

Setup time reduction Lot size reduction

Inventory reduction Removing Kanbans
Quality improvement Small group improvements
Defect free supplies Supplier collaborations

PUSH Scheduling
Internal
Focus

Long Lead
Times

Utilisation

Push

Quantity
Driven
Measurements

High
Demand
Forecast

High Fixed
Costs

INVENTORIES

Forecast drives production

PULL Scheduling
Profit Based
Measurement
Low
Demand
PULL
Finished Goods
External Focus
Factory

Flexibility

Faster
Response

Customer Order

Customer triggers production

PUSH PULL

Impact on the system

Kanban as Planning Tool

Terminologies

Preceding & Succeeding Processes

In-bound & Outbound Buffers
Design of Kanban System
Types of Kanbans
Production Order Kanban (P-Kanban)

Standard Containers

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Just in Time Manufacturing

JIT systems have an unambiguous definition of what
constitutes waste in the system.
The philosophy of Just in Time system is one of
continuous waste elimination.
Contrary to the traditional thinking, the inventory in a
JIT system is deliberately removed to expose hidden
problems.
These problems are solved resulting in fewer inventory
and waste in the system and greater productivity.
Implementation of JIT requires that the manufacturing
architecture is converted into a chain of internal
customers.
Lot size reduction and use of standard containers are
other elements of a JIT system.

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Just in Time Manufacturing

Production Planning and control in JIT systems
is achieved through the use of Kanban
Kanban enables waste elimination from the
system by preventing overproduction and
exposing problems in processes.

JIT systems utilise a Pull type scheduling

Pull type scheduling are very effective in
providing visible control of the processes and
bringing the problems to the surface rapidly.
The number of Kanbans required is a function of
production and conveyance lead time, size of
the standard container and the demand rate.
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Just in Time Manufacturing

Kaizen

Kai in the Japanese means change, while

zen means good (for the better),so that
kaizen means improvement.

Kaizen in Japanese means Continuous

Improvement in every sphere of Activity.
Kaizen is a sub-system of JIT.
The management encourages suggestions or
Kaizens from employees regarding possible
improvements in their respective work areas.
The employees are rewarded for giving a large
number of suggestions. These rewards are
more of recognitions , such as Kaizen Man of
the Month titles and certificates or small
gifts, rather than monetary worth.
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Just in Time Manufacturing

Andon
For error prevention and fault-finding, the operators
must notify supervisors and management when a
problem affects within the factory. To enable this, JIT
uses a portable andon system. The andon in the
Japanese means an ambulance-style flashing light
with a complementary siren. The operator puts the
andon on whenever he needs to draw the managements
attention, highlighting the importance of his problems.
By reacting to his call instantly, the management
ensures that customers are protected against receiving
defective products.
The andon system is not effective until most
problems are solved.
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Just in Time Manufacturing

Fixed Location Storage
JIT is successful only when there should be a fixed location
for all components, parts, tools and equipments. The
handling of parts and tools is minimised by properly
locating in the assembly area and in stores.
Fixed locations assist in knowing the exact location of parts
and the number of parts available for assembly. This ease
of access increases productivity and reduces damages to
components. The tools and equipments that are common
to all workers should be brought back to their locations
immediately after a worker finishes his work so that other
workers may use them these whenever required.

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