Pull Manufacturing and Just In Time

Superfactory Manufacturing Excellence Series

Lean Overview
5S & Visual Factory
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke & Mistake Proofing
Quick Changeover & SMED
Production Preparation Process (3P)
Pull Manufacturing & Just In Time
Standard Work
Theory of Constraints
Total Productive Maintenance
Training Within Industry (TWI)
Value Streams
Contents
• Introduction
• Background and History
• Components and Implementation
• Knowledge Check

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Introduction
• Just In Time (JIT) is an inventory strategy
implemented to improve the return on investment
of a business by reducing in-process inventory and
cycle time. The process is driven by a series of
signals, or Kanban, that tell production processes to
make the next part. When implemented correctly,
JIT can lead to dramatic improvements in a
manufacturing organization's return on investment,
quality, and efficiency.

© 2007 Superfactory™. All Rights Reserved. 3

Components and Implementation
• Pull vs. Push Scheduling
• The Problem of Inventory
• Just In Time
– Principles
– Benefits and Limitations
• Implementing JIT
– Kanban
– Pull Systems
– Quality
– One Piece Flow
– Continuous Flow
– Takt Time
• JIT and Suppliers
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Push Vs. Pull Scheduling
• Push Scheduling
– traditional approach
– “move the job on when finished”
– problems - creates excessive inventory

• Pull scheduling
– coordinated production
– driven by demand (pulled through system)
– extensive use of visual triggers
(production/withdrawal kanbans)

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Inventory Hides Problems

Work in process inventory level

(hides problems)

Unreliable Capacity
Scrap
Vendors Imbalances

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The Philosophy of JIT
• JIT means getting the right quantity of goods
at the right place and the right time
• Often termed “Lean Systems”
• All waste must be eliminated- non value
• items
Broad view that entire organization must
focus on serving customers
• JIT is built on simplicity- the simpler the
• better
Focuses on improving every operation-
• Kaizen
Install simple visible control systems
• Flexibility to produce different
models/features

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Elements of JIT Manufacturing
• JIT Manufacturing is a philosophy of value-added
manufacturing
• Achieved by
– Inventory reduction - exposes problems
– Kanbans & pull production systems
– Small lots & quick setups
– Uniform plant loading
– Flexible resources
– Efficient facility layouts

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JIT Tactics
• Single Minute Exchange of Dies (SMED)
• Statistical Process Control
• Use of standard containers
• Doable stable schedules with adequate
• TAKT-Time
visibility
• 5-S Program
• Kaizen Event
• Visual control
• Flexible workers
• Tools at the point of need
• Product redesign
• Group Technology
• Total Productive Maintenance

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JIT and Suppliers
• Few
• Nearby (if possible)
• Repeat business/Longer Term Agreements
• Analysis to enable desirable suppliers to
become or stay price competitive
• JIT Logistics:
– Frequent Deliveries/Smaller Quantities
– Exact Quantities
– Consumption initiates deliveries
– Deliveries directly to the point of use
• Perfect Parts
• Concurrent engineering design practices
© 2007 Superfactory™. All Rights Reserved. 10