jit, just in time, manufacturing, production, operations management, swati luthra

1. JUST-IN-TIME
MANUFACTURING
A PowerPoint Presentation
BY
SWATI(54),
MEENAL(39),
REENU(45),
JAYA(66)

2. WHAT IS JIT?
• 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.

3. HOW IT WORKS?

4. 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.

5. 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’

6. 7 WASTES
1)
2)
3)
4)
Waste of over production
Waste of waiting
Waste of transportation
Waste of Underutilization
of Employees
5) Waste of Inventory
6) Waste of motion
7) Waste of making defective
products

7. PRINCIPLES OF JIT
PRODUCTION

8. TOTAL QUALITY
MANAGEMENT
• Seek long-term
commitment
• Quality must be a
higher priority than cost
• Minimize Waste

9. 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

10. 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

11. INVENTORY MANAGEMENT
 Eliminate
Safety Stock = Zero Inventory
 Inventory is Evil
Water = Inventory
Material
handling
Poor
training
Traditional systems use
inventory (water) to buffer the
process from problems (rocks)
that cause disruption.
Break
downs
Material
quality
problems
Long
setups

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

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

14. HUMAN RESOURCE
MANAGEMENT
• Company-wide Involvement
– Motivation for
continuous
improvement
– Problem Solving
• Diversified Employees
• Management Support and
Empowerment of workforce

15. JIT MANUFACTURING
BUILDING BLOCKS
Ultimate
Goal
Supporting
Goals
A
balanced
rapid flow
Reduce setup
and lead times
Eliminate disruptions
Make the system flexible
Product
Design
Process
Design
Eliminate waste
Minimize inventories
Personnel
Elements
Manufacturing Planning

16. REQUIREMENTS OF JIT
• Respond to Customer
Requirements
• Integrate all Processes
• Employee Participation
• Company wide
Commitment to education
• Eliminate redundancy
• Reduce all Inventory
• Establish Continuous
Improvement Goals
• Use a pull Production
System
• Design products for
Manufacturing
• Develop Controllable
Production Processes
• Have Defect Prevention
Program
• Reduce Setup Times
• Build Products to
Specification

17. OBSTACLES IN
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

18. ADVANTAGES OF JIT
• High quality
• Flexibility
• Reduced setup times
• Reduced need for indirect labor
• Less waste
• Low warehouse cost
• Synchronization between production scheduling and work
hour

19. DISADVANTAGES OF JIT
• Time consuming
• No spare product to meet un expected order
• Supply Shock : If products do not reach on
time
• High risk factor

20. JIT IN 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.

21. • Seamless system that allows it to transmit its component
on requirements
• Willingness of suppliers to keep inventory on hand.

22. JIT IN SERVICES: MAC D
McDonald’s is the best example of JIT in
Services !

23. • 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 !

24. THANK YOU!!