UNIT : 6

DESIGN, DEVELOPMENT AND

MANAGEMENT OF
JIT MANUFACTURING SYSTEMS
Issues connected with JIT that needs
much more systematic analysis are:

• Design
• Development
• Management of JIT manufacturing.
Following are the points that need to be
addressed systematically in JIT manufacturing:

• Flow Analysis and plant configurations

• Comparison of JITs Kanban based PULL system with conventional PUSH type
planning and control systems
• Quality Management Systems for JIT

• HRM in JIT

• Interface of JIT with advanced Manufacturing technology

• Performance assessment in JIT

• JIT Purchasing

• Post costing Information system for JIT

• JITs potential for developing countries

• Potential for Small manufacturers

Plant Configurations and Flow Analysis for JIT
Manufacturing
Six distinct stages of development or plant configurations for JIT
manufacturing are:

 The Job Shop Configuration

 Dedicated lines, based on group technology
 Dedicated lines, Kanban driven
 Dedicated lines, physically linked forwards
 Single line running mixed models
 U-Turn Lines
 The Job Shop Configuration

It uses general purpose equipment: ex: welding equipment:

• Weld set up is high, hence th production runs and lot size are
high – in days, weeks resulting in considerable cycle stocks.

• They operate on Process layout, batch basis and requires more

shop paperwork to prioritize for jobs in queue and to account for
WIP etc.
Dedicated lines, based on group technology

Group of machines are dedicated to process a family or

group of similar part families.

2 types of confg. are possible: GT cells and GT flow

lines

• Significant reduction of inventory, shop paper.

• There are inventories of incoming parts but less WIP.
 Cont..
• GT operates on small lot size, and one item at a
time geared for daily schedule.

• Lines run in accordance to current needs.

• Workers move from line to line as the schedule

changes.

• In GT cells:

Workers are multi-skilled in order to enable them to

perform multiple operations and also the flexibility,
Adjust to change of parts requirements. Etc..
 Dedicated lines, Kanban driven

• Variation are adopted in this case.

• Kanban replaces daily schedule.
• System triggers production of parts only subsequent to
withdrawal by down stream operations.

• Machine control discipline is facilitated by work Centre making

precise no. of parts to fill the standard container.

• This system eliminates the need for Schedules and calls for
computer based schedule, shop floor control s/w and H/W
Dedicated lines, physically linked forwards

• Even kanban is eliminated, it is possible only when there is

close coupling of 2 adjacent processes. Ex: Weld and paint.

• Inventory at the end of the process is eliminated.

• If the lines are too long, decoupling of line is possible to

account for variability in output.
 Single line running mixed models

• GT is retained but dedicated lines are consolidated into a single line which is capable
of running mixed models.

• This is possible when setup time are reduced to the point where there is virtually no
delays in changing to different models.

• Labour intensive final assembly lines are easy to confg. In this way.

• This layout cut downs no. of work stations, amount of equipment's, floor space,
inventory, buffer stock.

• Implementation of Kanban is made easier. Communication with preceding work

Centre is simplified.
• Supervision and shop floor control is simplified, workers move from line to line as
different models are made.
 U-Turn Lines

• Widely used in TPS.

• Essence of this layout is entry and exit are at same
position.
• Advantage of this layout is flexibility to increase and
decrease necessary no. of workers adopting to
changes in demand.
• Either by adding or removing people in the inner area
of U shaped workplace.
 Cont..
• One unit of material can pass into entrance when
one unit of output leaves through exit.

• Each operation are performed by single worker,

hence WIP is with in the layout is constant.

• By keeping std. inventory at each machine, the

imbalance of operations among workers will be
visualized. There by evoking improvement process.

• This layout allows areas to be developed for specific

worker operations.
 Bird cage and Isolated Layouts

Bird Cage: each worker is made to handle multiple

machine of same type.

Its better than one worker - one machine layout. – It

increases production quantity per worker.

- Inventory of semi finished units at each machine will

increase. Hence layout doesn’t enable synch among
workstations and lead time increases.
 Isolated Layout

• It avoids excess semi finished inventory.

• Decreased conveyance time.
• Existence of multi function worker will enable
continuous and smooth flow among all the
machine.
• Ensures a continuous walking route with least
distance for each worker.
Limitation:
 Quality Management System for JIT

• Autonomation and Functional Quality

Management are the basic building blocks of
company wide quality control (CWQC)

• Purpose of CWQC : Provide assurance of the

highest, defect-free quality to customer

• Various functions with in company assumes

specific QA related responsibilities in CWQC.
• Quality is a mindset first, a set of methods, tools,
and techniques next.

• High quality effort is the immediate feedback of a

problem that is discovered, so that the problem
can be resolved quickly, before large no. of parts
are scrapped or reworked.

• System of QM that ideally suits JIT is called TQC