Just-In-Time Manufacturing

Matt Schmidt
Penn State University
OISM 470W

Just-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?

Just-In Time Manufacturing

JIT- A philosophy of continuous improvement

that puts emphasis on prevention rather than
correction, and demands a company wide focus
on quality.

JIT- operational management approach to

achieve world class manufacturing.

JIT- 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

Philosophy 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

efforts 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
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
Problem- Andon or siren/light

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

Company-wide Involvement

Motivation for continuous improvement

Problem Solving
High Employee Interaction

Build Pride In Workmanship

Human Resource Management

Self-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-In-Time philosophy?

Continuous Improvement

Summary
JIT- 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.
Hutchins, D. Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988.
OGrady, 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: Prentice-Hall,
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.
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.