Supply Chain Mgmt Jit
- 1. Just-In-Time (JIT) JIT : an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials, finished goods & work in process.
- 2. Just-In-Time (JIT) (Cont.) Management philosophy…Nothing produce until needed. Encompasses the successful execution of all production activities required from design to delivery of products. Common sense based/simple techniques
- 3. Just-In-Time (JIT) (Cont.) Minimize waste of time, energy, material & errors Minimize waste…in both factories: Manufacturing product & “Hidden” Attack/eliminate waste Value added to the final product philosophy … from customer ’s point of view
- 4. Just-In-Time (JIT) (Cont.) Expose problems Continuous improvement/ change Enforced problem solving approach
- 5. Goals Zero defects …reducing defects Zero inventory …Stockless production Zero setup time … SMED ---Single Minute Exchange of Dies Zero handling Zero break down
- 6. Goals (Cont.) Zero lead time Zero Transactions …reduced paperwork Zero disturbances …routine execution of schedules
- 7. Elements addressing Elimination of Waste Focused Factory …specialized Group Technology …Eliminate movement & queue time between operations Jidoka …Quality at the source stop line if necessary Total quality: an approach that encompasses all phases of a manufacturing organization.
- 8. Elements addressing Elimination of Waste (Cont.) Quality …Meeting a specific set of customer expectations Fitness for use, reliability, consistency, etc. Customer…external & internal
- 9. JIT Manufacturing JIT Manufacturing : Executing linear production : Production of necessary units in the necessary time with the objective of 0 Variance W.R.T. the schedule.
- 10. JIT Manufacturing (Cont.) No Inventories, No queues Minimum schedule variation Uniform plant loading Uninterrupted flow of materials Flow paced by market demands Flexibility, Visual Control (make problems visible to everyone), Reliability (of materials, people & equipment)
- 11. JIT Manufacturing (Cont.) Inventory hides problems such as poor quality, break downs, late deliveries, workers absence & tardiness, etc. Tightening the production system : Reducing the amount of inventory in the system “One less at a time”…(reducing the lot size) expose eliminate constraints
- 12. Pull System Produce only when material is needed downstream…(cue from the user not the planning source) Pull materials sequentially through the factory. Orders placed at end item level. Idle material is waste. Need discipline…(Good practices reinforced through training)
- 13. Push System Production authorized in anticipation of needs downstream…(cue is a work order from the planning system) Orders launched to meet due dates. Keep machines & people busy. NOTE : Planning is necessary under JIT to ensure the right amount of productive resources are scheduled/available to satisfy MPS/FAS
- 14. Kanban Production Control Systems Simple, paperless procedures Signals/visual systems Posted schedules Containers Standard size , small Factors: Material Handling consideration proximity of work centers
- 15. Kanban Production Control Systems (Cont.) Kanban…Cards Production Card---”P” Card: Part #, Quantity to be produced, Supply work center #, etc. Conveyance (Move) Card---”C” Card : Part #, Container Capacity, Source, Destination, etc. 1-card system : Move card and an empty space 2-card system
- 16. Setup Reduction Setup reduction is the process of reducing the time required to convert from production of the last good piece of unit A to the first good piece of unit B . use methods engineering/common sense. Ideal lot size = 1.
- 17. Setup Reduction (Cont.) Setup activities: External: Operations performed while the machine is running. Internal: Operations performed after the machine is stopped. Setup…responsibility of the operator.