Just-In-Time Systems

1. Just-In-Time Systems

2. JIT/Lean Production • Just-in-time: Repetitive production system in which processing and movement of materials and goods occur just as they are needed, usually in small batches • JIT is characteristic of lean production systems • JIT operates with very little “fat”

3. JIT Goals • Eliminate disruptions • Make system flexible • Reduce setup and lead times • Eliminate waste • Minimize WIP • Simplify the process

4. Sources of Waste • Waste form overproduction • Waste of waiting time • Transportation waste • Inventory waste • Processing waste • Waste of motion • Waste from product defects

5. JIT Building Blocks • Product design • Process design • Personnel/organizationalelements • Manufacturing planning and control

6. Product Design • Standard parts • Modular design • Quality

7. Process Design • Small lot sizes • Setup time reduction • Manufacturing cells • Limited work in process • Quality improvement • Production flexibility • Little inventory storage

8. Reduces inventory Less rework Less storage space Problems are more apparent Increases product flexibility Easier to balance operations Benefits of Small Lot Sizes

9. Production Flexibility • Reduce downtime by reducing changeover time • Use preventive maintenance to reduce breakdowns • Cross-train workers to help clear bottlenecks • Reserve capacity for important customers

10. Personnel/Organizational Elements • Workers as assets • Cross-trained workers • Continuous improvement • Cost accounting • Leadership/project management

11. Manufacturing Planning and Control • Level loading • Pull systems • Visual systems • Close vendor relationships • Reduced transaction processing

12. Pull/Push Systems • Pull system: System for moving work where a workstation pulls output from the preceding station as needed. (e.g. Kanban) • Push system: System for moving work where output is pushed to the next station as it is completed

13. Kanban Production Control System • Kanban is the Japanese word for card. • Paperless production control system • Authority to pull, or produce comes from a downstream process.

14. Ultimate Goal A balanced rapid flow Supporting Goals Reduce setup and lead times Eliminate waste Minimize inventories Eliminate disruptions Make the system flexible Building Blocks Product Design Process Design Personnel Elements Manufactur-ing Planning Summary JIT Goals and Building Blocks

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16. Buyer Suppler Tiered Supplier Network First Tier Supplier Suppler Suppler Second Tier Supplier Suppler Suppler Suppler Suppler Third Tier Supplier

17. Benefits of JIT Systems • Reduced levels of inventories • Reduced space requirements • Increased product quality • Reduced lead times • Greater flexibility in product mix

18. Benefits of JIT Systems (cont’d) • Smoother production flow • Increased productivity levels • Worker participation in problem solving • Pressure for good vendor relationships • Reduced need for indirect labor

19. Converting to a JIT System • Get top management commitment • Decide which parts need most effort • Obtain support of workers • Start by trying to reduce setup times • Gradually convert operations • Convert suppliers to JIT • Prepare for obstacles

20. Obstacles to Conversion • Management may not be committed • Workers/management may not be cooperative • Suppliers may resist

21. JIT in Service The basic goal of the demand flow technology in the service organization is to provide optimum response to the customer with the highest quality service and lowest possible cost. • Eliminate disruptions • Make system flexible • Reduce setup and lead times • Eliminate waste • Minimize WIP • Simplify the process