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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

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just in time manufacturing

Just-In-Time Manufacturing

Matt Schmidt

Penn State University

OISM 470W

just in time manufacturing2
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 manufacturing3
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
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
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management
principles of jit manufacturing6
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management
total quality 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 management8
Total Quality Management
  • Eliminate Quality Inspectors
  • Quality is everyone’s responsibility
  • Do it right the first time
principles of jit manufacturing9
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management
production 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 management11
Production Management
  • Reduced lot sizes= Shorter cycle times
  • Eliminate disruptions in the process
  • Standardized Parts/ Simplicity
production management12
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
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 manufacturing14
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management
supplier 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 management16
Supplier Management
  • Elimination inspection of parts
  • Information Systems
    • Eliminating barriers to information
  • Communicate problems to suppliers in a positive manner.
supplier relations at toyota
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 manufacturing18
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management
inventory management
Inventory Management
  • Eliminate Safety Stock = Zero Inventory
  • Reduce WIP
  • JIT is not an inventory control system
  • Reduction in inventory opens up space
slide20
Inventory hides problems in a process.

Water Level = Inventory

Rocks = Problems in the system

Boat = Company Operations

principles of jit manufacturing21
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource 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 management23
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
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.
implementation problems
Implementation Problems
  • Worker resistance
  • Lack of top management support
  • Lack of communication
  • Lack of formal training
most important question
Most Important Question
  • What phrase best describes the Just-In-Time philosophy?

Continuous Improvement

summary
Summary

JIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality.

references
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.

O’Grady, 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.