JUST-IN-TIME

MANUFACTURING

A PowerPoint Presentation

BY
SWATI(54),
MEENAL(39),
REENU(45),
JAYA(66)
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?
HISTORY

• Evolved 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.
FOLLOWERS

• Adopted by General Electrical in the USA in the 1980.

• Some companies referred JIT with different names:
i. TOYOTA – ‘Toyota System’
ii. IBM – ‘Continuous flow manufacturing’
iii. GE- ‘Management by sight’
iv. HEWLETT- PACKARD- ‘stockless production & repetitive
manufacturing system’
7 WASTES

1) Waste of over production

2) Waste of waiting
3) Waste of transportation
4) Waste of Underutilization
of Employees
5) Waste of Inventory
6) Waste of motion
7) Waste of making defective
products
PRINCIPLES OF JIT
PRODUCTION
 TOTAL QUALITY
MANAGEMENT

• Seek long-term
commitment

• Quality must be a
higher priority than cost

• Minimize Waste
PRODUCTION
MANAGEMENT

• Pull System vs. Push System

– Pull = Made to order
– Push = Made for inventory

• Communication Techniques
– Completion of task-Kanban
– Problem- Andon or siren/light

• Flexibility of the system

• Design For Testability

– Poka-Yoke= Mistake-proofing
 SUPPLIER
MANAGEMENT

• Establish Long Term Relationships with few

E.g. Toyota Productions
suppliers.

• Delivery of Parts = 100% Defect Free

– Where they are needed
– When they are needed
– The exact quantity

• Work Together
• Elimination of inspection of parts
INVENTORY MANAGEMENT
 Eliminate Safety Stock = Zero Inventory
 Inventory is Evil

Traditional systems use inventory

Water = Inventory (water) to buffer the process from
problems (rocks) that cause
disruption.
Poor Break Material
Material training
handling downs quality Long
problems setups
 JIT systems view inventory as waste and work to lower
inventory levels to expose and correct the problems (rocks)
that cause disruption.

Material Poor Material Long

Break quality
handling training downs problems setups
 Lowering the level of inventory is relatively easy to
do. However, the problems that arise must be
corrected
quickly … Otherwise, the process will flounder.

Poor
Material training setups
Break downs quality
handling problems
 HUMAN RESOURCE
MANAGEMENT

• Company-wide Involvement
– Motivation for
continuous
improvement
– Problem Solving

• Diversified Employees

• Management Support and

Empowerment of workforce
JIT MANUFACTURING
BUILDING BLOCKS

Ultimate A
Goal
balanced
rapid flow

Supporting Reduce setup

Goals and lead times
Eliminate disruptions Eliminate waste
Make the system flexible Minimize inventories

Product Process Personnel Manufactur-

Design Design Elements ing Planning
REQUIREMENTS OF JIT
• Respond to Customer • Use a pull Production
Requirements System
• Integrate all Processes • Design products for
• Employee Participation Manufacturing
• Company wide • Develop Controllable
Commitment to education Production Processes
• Eliminate redundancy • Have Defect Prevention
Program
• Reduce all Inventory
• Reduce Setup Times
• Establish Continuous
Improvement Goals • Build Products to
Specification
OBSTACLES
IN
CONVERSION

• Management not committed

• Workers not cooperative
• Decide which parts need most effort
• Start by trying to reduce setup times
• Gradually convert operations
• Convert suppliers to JIT
• Prepare for obstacles
• Suppliers may resist
 ADVANTAGES OF JIT

• High quality
• Flexibility
• Reduced setup times
• Reduced need for indirect labor
• Less waste
• Low warehouse cost
• Synchronization 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
 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
McDonald’s 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 I’m
Lovin’ It !
THANK
YOU!!