JIT MANUFACTURING

Anish Sohoni 115A6055

Vineeth Nair 212A6077
WHAT I S J I T ?

• JIT is a manufacturing
philosophy involving an
integrated set of
procedures/activities designed
to achieve a volume of
production using minimal
inventories.
• A highly coordinated processing
system in which goods move
through the system, and
services are performed, just as
they need.
HOW I T WORKS?
HISTORY

• Evolved in Japan after World War II, as a result of their

diminishing market share in the auto industry.
• Founded by Taiichi Ohno, a vice president of Toyota.
• Basically implemented in Toyota plant 1950, well
established after 1970.
FOLLOWERS

• Adopted by General Electrical in the USA in the 1980.

• Some companies referred JIT with different names:
i. TOYOTA – ‘Toyota System’
ii. IBM – ‘Continuous flow manufacturing’
iii. GE- ‘Management by sight’
iv. HEWLETT- PACKARD- ‘stockless production & repetitive
manufacturing system’
7 WASTES

1) Waste of over production

2) Waste of waiting
3) Waste of transportation
4) Waste of Underutilization
of Employees
5) Waste of Inventory
6) Waste of motion
7) Waste of making defective
products
PRINCIPLES OF J I T
PRODUCTION
 TOTAL QUALITY
MANAGEMENT

• Seek long-term
commitment

• Quality must be a
higher priority than cost

• Minimize Waste
PRODUCTION MANAGEMENT
• Pull System vs. Push System
– Pull = Made to order
– Push = Made for inventory

• Communication Techniques
– Completion of task-Kanban
– Problem- Andon or siren/light

• Flexibility of the system

• Design For Testability

– Poka-Yoke= Mistake-proofing
 SUPPLIER MANAGEMENT

• Establish Long Term Relationships with few

E.g. Toyota Productions
suppliers.

• Delivery of Parts = 100% Defect Free

– Where they are needed
– When they are needed
– The exact quantity

• Work Together

• Elimination of inspection of parts

INVENTORY MANAGEMENT
 Eliminate Safety Stock = Zero Inventory
 Inventory is Evil

Traditional systems use

process from problems )

that cause disruption.
Poor Material
Material Break
training
handling downs quality Long
problems setups
 JIT systems view inventory as waste and work to lower
inventory levels to expose and correct the problems (rocks)
that cause disruption.

Material
Material Poor quality Long
Break
handling training downs problems setups
 Lowering the level of inventory is relatively easy to do.
However, the problems that arise must be corrected
quickly … Otherwise, the process will flounder.

Poor Material
training
Material Break downs quality Long
handling problems setups
 HUMAN RESOURCE
MANAGEMENT

• Company-wide Involvement
– Motivation for
continuous
improvement
– Problem Solving

• Diversified Employees

• Management Support and

Empowerment of workforce
J I T MANUFACTURING
B U I L D I N G BLOCKS

Ultimate A
Goal balanced
rapid flow

Supporting Reduce setup

Goals and lead times
Eliminate disruptions Eliminate waste
Make the system flexible Minimize inventories

Product Process Personnel Manufactur-

Design Design Elements ing Planning
REQUIREMENTS OF J I T
• Respond to Customer • Use a pull Production
Requirements System
• Integrate all Processes • Design products for
• Employee Participation Manufacturing
• Company wide • Develop Controllable
Commitment to education Production Processes
• Eliminate redundancy • Have Defect Prevention
Program
• Reduce all Inventory
• Reduce Setup Times
• Establish Continuous
Improvement Goals • Build Products to
Specification
OBSTACLES I N
CONVERSION
• Management not committed
• Workers not cooperative
• Decide which parts need most effort
• Start by trying to reduce setup times
• Gradually convert operations
• Convert suppliers to JIT
• Prepare for obstacles
• Suppliers may
resist
 ADVANTAGES OF J I T

• High quality
• Flexibility
• Reduced setup times
• Reduced need for indirect labor
• Less waste
• Low warehouse cost
• Synchronization between production scheduling and work
hour
 DISADVANTAGES OF J I T

• Time consuming

• No spare product to meet un expected order

• Supply Shock : If products do not reach on

time

• High risk factor

 J I T I N GOODS :

• Leveraged JIT principles to make its manufacturing process

a success

• Leverage their suppliers to achieve the JIT goal

• Provide exceptionally short set up times to their customers

• Suppliers carry inventory instead of carrying it themselves.

• Has dependable suppliers with the ability to meet its

demanding lead time requirements.
• Seamless system that allows it to transmit its component
on requirements

• Willingness of suppliers to keep inventory on hand.

 J I T I N SERVICES: MAC D

McDonald’s is the best example of JIT in

Services !
• McDonald's doesn't begin to cook until a
customer has placed a specific order.

• The major benefits are better food at a lower

cost.

• Wastage is reduced along with an improvised

taste that makes you want to scream out I’m
Lovin’ It !
THANK YOU!!