JUST IN TIME

MANUFACTURING PHILOSOPHY
AGENDA

 Introduction
 Objectives of JIT
 Goals for achieving JIT
 Key elements of JIT
 Key elements to achieve JIT
 Other elements of successful JIT
INTRODUCTION

JIT is a philosophy of manufacturing

based on planned elimination of all wastes and
continuous improvement of productivity. The
ideal just-in-time production system produces
and delivers exactly the required number of
each component to the downstream operation
in the manufacturing sequence just at the time
when that component is needed.
OBJECTIVES OF JIT
The main objective of JIT is to eliminate the
following wastes,
 Waste of over production
 Waste of transportation
 Waste of stocks
 Waste of making defective products
 Waste of waiting
 Waste of processing
 Waste of motion
GOALS FOR ACHIEVING JIT

 Zero defects
 Zero inventories
 Zero setup time
 Zero handling
 Zero break downs
 Zero lead time
GOALS FOR ACHIEVING JIT

 Reduce lot sizes

 Preventive maintenance
 Flexible work force
 Require supply quality assurance
 Small lot conveyance
KEY ELEMENTS TO ACHIEVE JIT
GOALS
PULL SYSTEM PRODUCTION CONTROL
In this system, the order to make and
deliver parts at each workstation comes from
the down stream station that uses those parts.
When the supply of parts at a given
workstation is about to be exhausted, that
station orders the upstream station to produce
the parts and fill again the supply
KANBAN PRODUCTION CONTROL
SYSTEM
A kanban or “pull” production control system uses simple,
visual signals to control the movement of materials between work
centers as well as the production of new materials to replenish
those sent downstream to the next work center.  Originally, the
name kanban (translated as “signboard” or “visible record”)
referred to a Japanese shop sign that communicated the type of
product sold at the shop through the visual image on the sign (for
example, using circles of various colors to indicate a shop that
sells paint).  As implemented in the Toyota Production System, a
kanban is a card that is attached to a storage and transport
container.  It identifies the part number and container capacity,
along with other information, and is used to provide an easily
understood, visual signal that a specific activity is required.
KANBAN PRODUCTION CONTROL
SYSTEM
In Toyota’s dual-card kanban system,
there are two main types of kanban:

 1. Production Kanban: signals the need to

produce more parts
 2. Withdrawal Kanban (also called a "move"
or a "conveyance” kanban): signals the need
to withdraw parts from one work center and
deliver them to the next work center.
KANBAN PRODUCTION CONTROL
SYSTEM
Dual-card Kanban Rules:

 No parts are made unless there is a production kanban to

authorize production.  If no production kanban are in the “in
box” at a work center, the process remains idle, and
workers perform other assigned activities.  This rule
enforces the “pull” nature of the process control.
 There is exactly one kanban per container.
 Containers for each specific part are standardized, and
they are always filled with the same (ideally, small)
quantity.  (Think of an egg carton, always filled with exactly
one dozen eggs.)
KANBAN PRODUCTION CONTROL
SYSTEM
KANBAN PRODUCTION CONTROL
SYSTEM
KANBAN PRODUCTION CONTROL
SYSTEM
KEY ELEMENTS TO ACHIEVE JIT
GOALS
HIGH QUALITY
JIT systems eliminate all defects,
which eliminates the scrap and rework
that help to provide a smooth flow of
materials through the plant. The quality
is built into the process and is controlled
by workers acting as their own quality
inspectors.
KEY ELEMENTS TO ACIEVE JIT
GOALS
SMALL BATCH SIZE AND REDUCED
SETUP TIME
Batch size and setup time must be
minimized to minimize WIP inventories.
Reduced setup time permit smaller
batches and lower WIP levels. Setup
time may be reduced by the following
approaches.
KEY ELEMENTS TO ACIEVE JIT
GOALS
 Design the setup tooling and plan the
setup method to permit changeover
procedure as much as possible.
 Use time and motion study to reduce the
setup procedure to the fewest possible.
 Eliminate or minimize adjustments in the
setup
KEY ELEMENTS TO ACHIEVE JIT
GOALS
 Use quick acting clamping devices
instead of bolts and nuts.
 Use group technology and cellular
manufacturing so that similar part styles
are produced on the same equipment.
OTHER REQUIREMENTS FOR
SUCCESSFUL JIT PRODUCTION
 Stable production schedules
 On-time delivery
 Defect free components and materials
 Reliable production equipment
 A work force that is capable, comitted
and co-operative
 A dependable supplier base