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Just-In-Time Manufacturing

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Title: Just-In-Time Manufacturing


1
Just-In-Time Manufacturing
  • Matt Schmidt
  • Penn State University
  • OISM 470W

2
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?

3
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

4
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.

5
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management

6
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management

7
Total Quality Management
  • Seek long-term commitment to quality efforts with
    continuous improvement
  • Quality must be a higher priority than cost
  • Minimizing waste

8
Total Quality Management
  • Eliminate Quality Inspectors
  • Quality is everyones responsibility
  • Do it right the first time

9
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management

10
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

11
Production Management
  • Reduced lot sizes Shorter cycle times
  • Eliminate disruptions in the process
  • Standardized Parts/ Simplicity

12
Production Management
  • Communication Techniques
  • Completion of task-Kanban
  • Problem- Andon or siren/light
  • Stopping the process if something goes wrong
    Jidoka
  • Preventive Maintenance

13
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.

14
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management

15
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

16
Supplier Management
  • Elimination inspection of parts
  • Information Systems
  • Eliminating barriers to information
  • Communicate problems to suppliers in a positive
    manner.

17
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.

18
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management

19
Inventory Management
  • Eliminate Safety Stock Zero Inventory
  • Reduce WIP
  • JIT is not an inventory control system
  • Reduction in inventory opens up space

20
  • Inventory hides problems in a process.
  • Water Level Inventory
  • Rocks Problems in the system
  • Boat Company Operations

21
Principles Of JIT Manufacturing
  • Total Quality Management
  • Production Management
  • Supplier Management
  • Inventory Management
  • Human Resource Management

22
Human Resource Management
  • Company-wide Involvement
  • Motivation for continuous improvement
  • Problem Solving
  • High Employee Interaction
  • Build Pride In Workmanship

23
Human Resource Management
  • Self-Inspection of work
  • Diversified Employees
  • Absenteeism
  • To eliminate boredom in process
  • Management Support and Empowerment of workforce

24
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.

25
WIP Example
26
Implementation Problems
  • Worker resistance
  • Lack of top management support
  • Lack of communication
  • Lack of formal training

27
Most Important Question
  • What phrase best describes the
    Just-In-Time philosophy?
  • Continuous Improvement

28
Summary
  • JIT- A philosophy of continuous improvement
    that puts emphasis on prevention rather than
    correction, and demands a company wide focus on
    quality.

29
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.
  • OGrady, 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.
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