Just-In-Time Manufacturing?

 What is JIT Manufacturing?

 Where did it come from?

 What are the main principles?

 Is it easy to Implement?

 What phrase best describes JIT?

 Just-In Time Manufacturing

 JIT- A philosophy of continuous improvement that puts emphasis

on prevention rather than correction, and demands a company
wide focus on quality.

 JIT- operational management approach to achieve world class

manufacturing.

 JIT- production is based on demand

 History of JIT Manufacturing

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

market share in the auto industry.

 Toyota Motor Company- Birthplace of the JIT Philosophy Under Taiichi

Ohno.
• W. Edwards Deming
• 14 points for Management

 JIT is now on the rise in American Industries.

 Principles Of JIT Manufacturing
 Total Quality Management

 Production Management

 Supplier Management

 Inventory Management

 Human Resource Management

 Principles Of JIT Manufacturing
 Total Quality Management
 Production Management

 Supplier Management

 Inventory Management

 Human Resource Management

 Total Quality Management

 Seek long-term commitment to quality efforts with

continuous improvement

 Quality must be a higher priority than cost

 Minimizing waste
 Total Quality Management
 Eliminate Quality Inspectors

 Quality is everyone’s responsibility

 Do it right the first time

 Principles Of JIT Manufacturing
 Total Quality Management

 Production Management

 Supplier Management

 Inventory Management

 Human Resource Management

 Production Management
 Pull System vs. Push System
• Pull = Made to order
• Push = Made for inventory

 Flexability of the system

 Design For Testability – In the process

• Poka-Yoke= Mistake-proofing
• Throughout entire process
 Production Management

 Reduced lot sizes= Shorter cycle times

 Eliminate disruptions in the process

 Standardized Parts/ Simplicity

 Production Management
 Communication Techniques
• Completion of task-Kanban
• Problem- Andon or siren/light

 Stopping the process if something goes wrong =Jidoka

 Preventive Maintenance
 Production Management at Toyota
 Toyota uses a Kanban pull system throughout the
production process.

 Each task in the process seems to take identical length

and work content, so everyone is working at the same
pace to reduce bottlenecks.
 Principles Of JIT Manufacturing
 Total Quality Management

 Production Management

 Supplier Management

 Inventory Management

 Human Resource Management

 Supplier Management
 Establish Long Term Relationships with few suppliers.

 Delivery of Parts = 100% Defect Free

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

 Work Together
 Supplier Management
 Elimination inspection of parts

 Information Systems
• Eliminating barriers to information

 Communicate problems to suppliers in a positive manner.

 Supplier Relations at Toyota
 Toyota communicates their damand for parts 20 days in
advance to their suppliers, with the right to change the
forecast up to the 10th day.
 Principles Of JIT Manufacturing
 Total Quality Management

 Production Management

 Supplier Management

 Inventory Management
 Human Resource Management
 Inventory Management

 Eliminate Safety Stock = Zero Inventory

 Reduce WIP

 JIT is not an inventory control system

 Reduction in inventory opens up space

Inventory hides problems in a process.

Water Level = Inventory

Rocks = Problems in the system
Boat = Company Operations
 Principles Of JIT Manufacturing
 Total Quality Management

 Production Management

 Supplier Management

 Inventory Management

 Human Resource Management

 Human Resource Management
 Company-wide Involvement
• Motivation for continuous improvement
• Problem Solving
• High Employee Interaction

 Build Pride In Workmanship

 Human Resource Management

 Self-Inspection of work

 Diversified Employees
• Absenteeism
• To eliminate boredom in process

 Management Support and Empowerment of workforce

Human Resource Management at Toyota

 In 1986 from a labor force of 60,000 Toyota received 2.6

million improvement proposals, 96% of which were
implemented by either management or the employees
themselves.
WIP Example
 Implementation Problems

 Worker resistance

 Lack of top management support

 Lack of communication

 Lack of formal training

 Most Important Question
 What phrase best describes the Just-In-Time
philosophy?

Continuous Improvement
 Summary

JIT- A philosophy of continuous improvement that puts

emphasis on prevention rather than correction, and
demands a company wide focus on quality.
 References

Cammaranano, J. Lessons to be Learned: JIT. Atlanta, Georgia: Engineering and Management Press, 1997.
Dear, A. Working toward JIT: Management Technology. London: Derek Doyle and Associates, 1988.
Fisher, D. The JIT Self Test: Success Through Assesment and Implementation. Chicago, IL: Irwin Inc., 1995.
Hernandez, A. JIT Quality: A Practical Approach. Englewood Cliffs, NJ: Prentice-Hall, 1993.
Hutchins, D. Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988.
O’Grady, P.J. Putting the JIT Philosophy Into Practice. New York, NY: Nichols Publishing, 1988.
Reinfeld, N.V. Handbook of Production and Inventory Control. Englewood Cliffs, NJ: Prentice-Hall, 1987.
Schneiderjans, M.J. Advanced Topics In JIT Management: JIT Systems. Westport, CT: Greenwood Publishing Group, 1999.
Taver, R.W. Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Problem Solving Process . New York,
NY: AMACON, 1995.
Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Winning with Quality: Applying Quality Principles in Product Development.
Reading, MASS: Addison-Wesley Publishing Co., 1995.