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JIT (Just In Time)
• Think of a situation where we produce goods only at the time when they are needed and in the quantity that is needed
No WIP & FG inventories Suppliers convinced – no RM inventory zero or equal to zero inventory
• Concept borrowed from American supermarkets • Its not an inventory management system but rather a business philosophy JIT is about making the right quantity products in right time with zero defects (i.e right quality)
Goals Of JIT • • • • • Produce goods that customers want Operate at customers rate Ensure perfect quality Zero unnecessary lead time Optimum utilisation of resources GOAL of JIT is to have ideal production system 3 .
70% of set-up time can be reduced Single setup and one touch setups Shift from “fix it when it breaks” to zero break-downs Acceptable quality level (AQL) • Smoothing of production o • Short set-up times o o • Improved Maintenance o • Improved Quality o JIT encourages good quality products within set cycle time 4 .Requirements for an effective JIT system • Yo-i-don (Ready-set-go) and Standardisation o o All have same pre-planned cycle time Andon (red light) after finishing Breaking huge production task to single unit targets 50% .
contd • Multiskilling o PDCA Produce and supply materials when required Take responsibility for quality Attitude to produce zero defects Vision and good leadership • Vendor Management o o • Self Discipline o • Commitment of Top Management o JIT cannot be quickly put in place and forgotten. Implementation requires a total commitment to operate in a better way – a way of doing things right 5 Inattention is unforgivable . .Requirements for an effective JIT system .
Benefits of JIT • • • • • • • No Inventory or Lot size No Waiting time Improved Quality Lower cycle time / lead time High variety available Faster market response Less investment in manufacturing and material handling facilities JIT is capable of taking large and sudden variations in demand pattern 6 .
Elements of JIT • JIT Production Produce what is required • JIT Distribution Third Party Logistics Multiple product loading • JIT Purchasing Have quality certified. less number of suppliers 7 .
KANBAN • Kanban is an information system used to control the number of parts produced in every process • Forms / Types of Kanban Vendor Kanban Withdrawal Kanban Production order Kanban 8 .
How Kanban works Outbound Stock Point Completed parts with cards enter Outbound Stock Point Outbound Stock Point When production is removed. place production cards in hold box Production card authorises start of work Production card Workstation Standard container Kanban card Stock point 9 .
least thinking is done in this area 11 . stopping any process immediately once the problem or error is detected • It is intelligent enough to assess what is going on & act accordingly.JIDOKA • The second pillar of TPS. referred to as “automation with human face” or autonomation • It allows the control system to supervise manufacturing. as an human being might Inspite of being the second pillar of TPS.
Components of JIDOKA • Andon • Poka yoke • Autonomation • Total Productive Maintenance (TPM) 12 .
It means HELP With Andon if the problem is not fixed before it reaches fixed position stop. the line will STOP 13 .Andon • Andon doesn’t means STOP the process.
Benefits of Andon •Process Control •First time quality •Rapid response •Instant Feedback •Teamwork •Productivity •Improved communications •Status at a glance 14 .
Components of JIDOKA • Andon • Poka yoke • Autonomation • Total Productive Maintenance (TPM) 15 .
Poka Yoke • The practice of striving towards zero defects by using techniques. standards and devices to prevent errors Error proofing devices should be: • Simple • Easy to install • In expensive • Developed by user • Considered at design stage 16 .
lights etc. To CONTROL the process • Devices or techniques are used to stray away from standard operating procedures or to keep defective goods from being passed on to the next stage 3. To STOP the process A device or technique is used to detect an abnormal or defective operation and stop the process 2. to signal that a defect or abnormal operation is occurring or about to occur 17 .Role of mistake proofing device 1. To WARN that an error is about to occur Use of buzzers.
Operation step method • • During process and between process Compare what operators are doing against the Standard Operating Procedures (SOP) 3.Steps for implementing mistake proofing 1. Specify / check item characteristics Shape. Dimensions & Weight 2. Statistical Method • Counting. Remainder & Critical Condition 18 .
Components of JIDOKA • Andon • Poka yoke • Autonomation • Total Productive Maintenance (TPM) 19 .
Autonomation • Human intelligence transferred to automated machinery to detect problems (defect) and automatically stop themselves • Purpose is to prevent or detect defects 20 .
Components of JIDOKA • Andon • Poka yoke • Autonomation • Total Productive Maintenance (TPM) 21 .
Total Productive Maintenance (TPM) GOALS •Eliminate all machine breakdowns HOW •Cleaning. tightening & lubricating •Inspect initial symptoms •Achieve a 100% on demand utilisation rate Main GOAL of TPM is the machine should work & work well when needed the most •Adhere to standard work •Operator alertness •Root cause analysis 22 .
Role of operator in TPM Main Role •Operate •Inspect •Maintain •Clean •Adjust •Record Problems Support Role •Report Abnormalities •Assist maintenance •Troubleshoot •Modify TPM if needed •Participate in problem solving and special project teams 23 .