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Just-In-Time Systems. JIT/Lean Production. Just-in-time : Repetitive production system in which processing and movement of materials and goods occur just as they are needed, usually in small batches JIT is characteristic of lean production systems JIT operates with very little “fat”.

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jit lean production
JIT/Lean Production
  • Just-in-time: Repetitive production system in which processing and movement of materials and goods occur just as they are needed, usually in small batches
  • JIT is characteristic of lean production systems
  • JIT operates with very little “fat”
jit goals
JIT Goals
  • Eliminate disruptions
  • Make system flexible
  • Reduce setup and lead times
  • Eliminate waste
  • Minimize WIP
  • Simplify the process
sources of waste
Sources of Waste
  • Waste form overproduction
  • Waste of waiting time
  • Transportation waste
  • Inventory waste
  • Processing waste
  • Waste of motion
  • Waste from product defects
jit building blocks
JIT Building Blocks
  • Product design
  • Process design
  • Personnel/organizationalelements
  • Manufacturing planning and control
product design
Product Design
  • Standard parts
  • Modular design
  • Quality
process design
Process Design
  • Small lot sizes
  • Setup time reduction
  • Manufacturing cells
  • Limited work in process
  • Quality improvement
  • Production flexibility
  • Little inventory storage
benefits of small lot sizes

Reduces inventory

Less rework

Less storage space

Problems are more apparent

Increases product flexibility

Easier to balance operations

Benefits of Small Lot Sizes
production flexibility
Production Flexibility
  • Reduce downtime by reducing changeover time
  • Use preventive maintenance to reduce breakdowns
  • Cross-train workers to help clear bottlenecks
  • Reserve capacity for important customers
personnel organizational elements
Personnel/Organizational Elements
  • Workers as assets
  • Cross-trained workers
  • Continuous improvement
  • Cost accounting
  • Leadership/project management
manufacturing planning and control
Manufacturing Planning and Control
  • Level loading
  • Pull systems
  • Visual systems
  • Close vendor relationships
  • Reduced transaction processing
pull push systems
Pull/Push Systems
  • Pull system: System for moving work where a workstation pulls output from the preceding station as needed. (e.g. Kanban)
  • Push system: System for moving work where output is pushed to the next station as it is completed
kanban production control system
Kanban Production Control System
  • Kanban is the Japanese word for card.
  • Paperless production control system
  • Authority to pull, or produce comes from a downstream process.
summary jit goals and building blocks

Ultimate

Goal

A

balanced

rapid flow

Supporting

Goals

Reduce setup

and lead times

Eliminate waste

Minimize inventories

Eliminate disruptions

Make the system flexible

Building

Blocks

Product

Design

Process

Design

Personnel

Elements

Manufactur-ing Planning

Summary JIT Goals and Building Blocks
slide15

Buyer

Suppler

Suppler

Suppler

Suppler

Suppler

Suppler

Suppler

Traditional Supplier Network

slide16

Buyer

Suppler

Tiered Supplier Network

First Tier Supplier

Suppler

Suppler

Second Tier Supplier

Suppler

Suppler

Suppler

Suppler

Third Tier Supplier

benefits of jit systems
Benefits of JIT Systems
  • Reduced levels of inventories
  • Reduced space requirements
  • Increased product quality
  • Reduced lead times
  • Greater flexibility in product mix
benefits of jit systems cont d
Benefits of JIT Systems (cont’d)
  • Smoother production flow
  • Increased productivity levels
  • Worker participation in problem solving
  • Pressure for good vendor relationships
  • Reduced need for indirect labor
converting to a jit system
Converting to a JIT System
  • Get top management commitment
  • Decide which parts need most effort
  • Obtain support of workers
  • Start by trying to reduce setup times
  • Gradually convert operations
  • Convert suppliers to JIT
  • Prepare for obstacles
obstacles to conversion
Obstacles to Conversion
  • Management may not be committed
  • Workers/management may not be cooperative
  • Suppliers may resist
jit in service
JIT in Service

The basic goal of the demand flow technology in the service organization is to provide optimum response to the customer with the highest quality service and lowest possible cost.

  • Eliminate disruptions
  • Make system flexible
  • Reduce setup and lead times
  • Eliminate waste
  • Minimize WIP
  • Simplify the process