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


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
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


E.g. Toyota Productions
Material
quality
problems
Long
setups
Poor
training
Break
downs
Material
handling
Traditional systems use
inventory (water) to buffer the
process from problems (rocks)
that cause disruption.
Water = Inventory
INVENTORY MANAGEMENT
Eliminate Safety Stock = Zero Inventory
Inventory is Evil

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

Company-wide Involvement
Motivation for
continuous
improvement
Problem Solving

Diversified Employees

Management Support and
Empowerment of workforce


JIT MANUFACTURING
BUILDING BLOCKS
Product
Design
Process
Design
Personnel
Elements
Manufactur-
ing Planning
Eliminate disruptions
Make the system flexible
Reduce setup
and lead times
Eliminate waste
Minimize inventories
A
balanced
rapid flow
Ultimate
Goal
Supporting
Goals
REQUIREMENTS OF JIT
Respond to Customer
Requirements
Integrate all Processes
Employee Participation
Company wide
Commitment to education
Eliminate redundancy
Reduce all Inventory
Establish Continuous
Improvement Goals


Use a pull Production
System
Design products for
Manufacturing
Develop Controllable
Production Processes
Have Defect Prevention
Program
Reduce Setup Times
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
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 !