Just in Time
Meaning.
Big JIT and Little JIT.
Waste and its types.
Elements that address minimization of waste.
JIT implementation requirements.
JIT meaning
an integrated set of activities designed to achieve high
volume production
using minimal inventories of raw materials, work in
process, and finished goods.
is also based on the logic that nothing will be
produced until it is needed.
Big JIT and Little JIT
Big JIT
Often termed as lean production.
is the philosophy of operations management
that sees to eliminate waste in all aspects of a firm’s
production activities, human relations, vendor
relations, technology, and the management of
materials and inventories.
Little JIT
Focuses more narrowly on scheduling goods
inventories and
providing services resources where and when needed.
Japanese approach to productivity
Is based on two philosophy ie
– Elimination of waste
– Respect for people
Elimination of waste: Toyota’s
Fujio Cho concept
anything other than minimum amount of equipment,
materials, parts, and workers (working time)
which are absolutely essential to production.
Waste to be eliminated
i. Waste from over production
ii. Waste of waiting time.
iii. Transportation waste.
iv. Inventory waste
v. Processing waste
vi. Waste of motion
vii. Waste from product defects
Elimination of waste
Seven elements that address elimination of waste
i. Focused factory network
ii. Group technology
iii. Quality at the source
iv. JIT production
v. Uniform plant loading
vi. Kanban production control system
vii. Minimize set up time
Focused Factory Network
The Japanese build small specialized plants rather
than large vertically integrated manufacturing
facilities.
They find large operations and their bureaucracies
difficult to mange and not in line with their
management style
Group technology:
Instead of transferring from one department to
another to specialized workers, The Japanese consider
all operations required to make a part and group those
machines together.
The group technology cells eliminate movement and
queue (waiting) time between operations,
reduce inventory, and reduce the number of
employees required.
Quality at the source:Jidoka
It means do it right the first time ,
when something goes wrong, stop the process or
assembly line immediately.
Factory workers become their own inspectors,
personally responsible for the quality of their
outputs.
Quality at the source
Quality at the source includes automation or
automated inspection.
Japanese prefer to have quality inspections performed
by automation or robotics because it is faster, easier,
repeatable and suitable for jobs too redundant for a
worker to perform.
JIT production:
JIT means producing what is needed when needed
and no more.
Anything over the minimum amount necessary is
viewed as waste,
because effort and material expended for something
not needed now cannot be utilized now.
The what’s of JIT
What it is What it does
– Mgt philosophy – Attack waste
– Pull system through the – Exposes problems and
plant bottlenecks
What it requires
What it assumes
– Employee participation
– Stable environment
– CI
– TQC
– Small lot size
Uniform plant loading:
Smoothing the production flows to dampen/reduce
the reaction waves that normally occurs in response
to schedule variations is called uniform plant loading.
When a change is made in a final assembly, the
changes are magnified throughout the line and the
supply chain.
The only way to eliminate the problem is to make
adjustments as small as possible by setting a firm
monthly production plan for which the output rate is
frozen .
Kanban production control:
Kanban means “sign” or “instruction” card in
Japanese.
A Kanban control system uses a signaling device to
regulate JIT flows.
The cards or containers make up the Kanban pull
system.
The number of Kanban card sets is
=DL(1+S)/C
where DL Expected demand during lead time and S=
safety stock and C= Size of the container
Some approaches of Kanban
Container system
– Container can be used as signal device
– An empty container on the factory floor visually signals
the need to fill it.
Kanban square
– Some company use marked spaces on the floor or on the
table to identify where material should be stored.
Minimized set up times
Because small lot sizes are the norm, machine setups
must be quickly accomplished to produce the mixed
models on the line.
To achieve set up time reduction, setups are divided
into internal and external activities.
Internal setup must be done while a machine is
stopped.
External set up can be done while the machine is
running.
Respect for people
Respect for people is a key to the Japanese
improvements.
They have traditionally stressed lifetime employment
for permanent positions with in major firms.
Companies try to maintain level payrolls even when
the business condition deteriorates.
Respect for people
Permanent workers (about one third of the total work
forces) have job security
and tend to be more flexible, remain with a company,
and do all they can to helps firm achieve its goal.
Mgt view worker as asset not as human machine
Respect for people
Bottom round mgt: style made up of consensus mgt
by committees or teams.
Quality circle:Volunteer employees meet weekly to
discuss their job and problems
They attempt to device a solution of the problem and
share the solution with mgt.
JIT implementation
requirements
It discusses ways to accomplish JIT production. It
follows some steps. They are:
Design flow process:
Total quality control
Stabilize schedule
Kanban Pull
Work with vendor
Reduce inventory more
Improve product design
JIT implementation requirement
a. Kanban Pull: By demand pull, Back flush, reduce
lot sizes.
b. Work with vendors: Reduce lead times, frequent
deliveries, project usage requirements, quality
expectation.
c. Reduce inventory more: Look for other areas:
stores, transit, carousels, conveyors.
d. Improve product design: Standard product
configuration, standardize and reduce number of
parts, process design with product design, quality
expectation.
Design flow process
JIT requires the plant layout to be designed to ensure
balanced work flow with a minimum of work in
process inventory.
This is done by link operations, balance workstations
capacities, emphasize preventive maintenance,
reduce lot size, and reduce setup/ change over time.
Total quality control
TQC is the practice of building quality into the process
and not identifying quality by inspection.
A stable schedule
JIT firms require a stable schedule over a lengthy
time horizon.
This is accomplished by
level scheduling: pull material into final assembly by a
uniform pattern.It allows various element of production
to respond perfectly.
Freeze windows:period of time during which schedule
is fixed and no further changed is possible.
Underutilization of capacity:Is realized when buffer
inventories are removed.
CT2 marks:10 Time:30 minutes.
i. What is TQM? List the elements of TQM. Explain tools for the QC dept.
ii. For a particular component X Alpha has a LTPD of 10 percent. Zenon
corporation, from whom Alpha purchases this component, has an
acceptable quality level in its production facility of 3 percent for
component X. Alpha has a consumer’s risk of 10 percent and Zenon has a
producer’s risk of 5 percent.
– When a shipment of product X is received from Zenon corporation what is the
sample size that the receiving department should test?
– What is the allowable number of defects in order to accept the shipment?
iii. What is line balancing? Explain types of Layout
(any two).
