J i-t
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This document discusses Just-in-Time (JIT) systems and Lean production. JIT operates with very little inventory and is responsive to customers by producing goods just as they are needed in small batches. It aims to eliminate waste through a focus on customer value. JIT uses a pull system where components are pulled through production as needed rather than being pushed. Key aspects of JIT include attacking waste, exposing problems, streamlining production through reduced inventory and simplified execution. JIT characteristics include a steady production rate, low inventories, small lot sizes, quick changeovers, and empowered flexible workers. The goal is a balanced rapid flow through the production system.
J i-t
- 2. JIT 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 Is characteristic of lean production systems Lean Production: A way to eliminate Waste through a focus on exactly what the customer wants. Operates with very little material Is very responsive to customers
- 3. JIT vs. MRP II Similar goals Right products, right place, right time MRP II Computer-based, manages complexity JIT Manual systems, simplicity/execution
- 4. Just-In-Time Concepts jit - Inventory/production control system Supplies and components are ‘pulled’ through system to arrive where they are needed when they are needed. Pull System: A JIT concept that results in material being produced only when requested and moved to where it is needed just as it is needed. JIT - Management philosophy of continuous improvement and forced problem solving
- 5. Multi-aspect approach High quality, quick response, flexibility Attacks waste Anything not adding value to product (customer view) Exposes problems and bottlenecks caused by variability Any deviation from the optimum process Achieves streamlined production (pull system) Reduced inventory Simplified Execution What Does Just-in-Time Do?
- 6. Waste is ‘anything other than the minimum amount of equipment, materials, parts, space, and worker’s time, which are absolutely essential to add value to the product.’ — Shoichiro Toyoda President, Toyota © 1995 Corel Corp. Waste
- 7. Variability Employees, machines, and suppliers produce units that do not conform to standards, are late, or are not the proper quantity Engineering drawings or specifications are inaccurate Production personnel try to produce before drawings or specifications are complete Customer demands are unknown
- 8. Push versus Pull Push system: material is pushed into downstream workstations regardless of whether resources are available Pull system: material is pulled to a workstation just as it is needed
- 9. JIT Characteristics A Fixed, Steady Rate of Production Uniform flow/communicated to vendors Low Inventories Less space, investment Uncover defects Small Lot Sizes Less Work in process Fast feedback Quick, Low Cost Setups Preventive Maintenance & Repair
- 10. JIT Characteristics Empowered Workers Multifunctional/Cooperative (Guerilla squad) Flexible capacity High Quality Levels On-going production Small/frequent deliveries Product simplification Standardization Fewer part numbers/drawings
- 11. JIT Characteristics Reliable Suppliers Dock-to-stock Much fewer in number Long-term relationships A Pull System of Moving Goods Request-based Commitment to Problem Solving/ Continuous Improvement
- 12. JIT Building Blocks Product Design Process Design Personnel Elements Manufactur- ing Planning Eliminate disruptions Make the system flexible Reduce setup and lead times Eliminate waste Minimize inventories A balanced rapid flow Ultimate Goal Supporting Goals Building Blocks
- 13. JIT in Services All the techniques used in manufacturing are used in services SuppliersSuppliers LayoutsLayouts InventoryInventory SchedulingScheduling
- 14. Converting to a JIT System Top management commitment Prioritize efforts Worker support Start by reducing setup times Gradually convert operations Convert suppliers to JIT Prepare for obstacles
- 15. Obstacles to Conversion Management not committed Workers not cooperative Suppliers may resist
- 16. JIT & Operations Planning and Control MRP as planning tool Pull systems Closer relationships with fewer vendors Reduced transaction processing
- 17. Attributes of Lean/JIT Producers build systems to help employees produce a perfect part every time reduce space requirements develop close relationships with suppliers educate suppliers eliminate all but value-added activities develop the workforce make jobs more challenging reduce the number of job classes and build worker flexibility
Editor's Notes
- #8: It would also be useful if you could have students develop a similar list for services.
- #14: Ask your students to provide some examples. A useful assignment if you have the time is to ask your students to develop a treatment parallel to that which you and the slides have just presented - but oriented toward services.