JIT – Just-In-Time Production

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 Introduction to JIT

Overview of JIT
 JIT is a pull production system

Catch Phrase
 “The right part in the right place at the right
time”

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 History of JIT

Taiichi Ohno of the Toyota Motor Corporation

is often referred to as “The Father of JIT.” The
JIT management philosophy has been around
since the 1950’s, which is when Ohno first
started developing and practicing JIT concepts
within the Toyota Corporation. Ohno titled his
new methods of production the Toyota
Production System (TPS), which has now
become a synonymous term for JIT

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 Toyota’s Lean Production House

Goal: highest quality, lowest cost, shortest leadtime

Just in Time (JIT) –

Jidoka JIT continuous flow, pull
system, or kanban

Heijunka 5S Standardized Work Kaizen

Stability – Stable Manufacturing Processes, 100% Quality, Total Preventative Maintenance

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 Synonyms for JIT

Toyota Production System

Stockless production
Lean production
Kanban system

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 JIT Goal and Philosophies
GOAL of JIT:
Production control through waste elimination
Philosophy of JIT
 Elimination of waste
 Broad view of operations
 Simplicity
 Continuous improvement
 Visibility
 Flexibility

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 JIT Principles

Simplification
Cleanliness and organization
Visibility
Cycle timing
Agility
Variation reduction
Measurement

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 Elements of JIT

Meet daily Reveal non-value added

Discuss work practices practices
Reduce buffer stock Involve the workforce:
consultation instead of
Modify machinery –
confrontation
reduced setup
Expose problems

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 Benefits of JIT

Better quality products Less inventory

Reduced scrap and rework Higher productivity
Reduced cycle times Most skilled workforce
Lower setup times Reduced space
Smoother production flow requirements
Cost savings Higher work participation

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 Toyota’s Seven Wastes

Producing defects
Transportation
Inventory
Overproduction
Waiting Time
Processing
Motion

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 Canon’s Nine Wastes
Work-in-process
Defects
Equipment
Expense
Indirect labor
Planning
Human resources
Operations
Startup
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 The Five Why’s

Ask “Why” five times to get to the source

of waste and the cause of problems
1. Why did the machine stop? Overload and
blown fuse
2. Why the overload? Not lubricated
3. Why not lubricated? Oil pump not pumping
4. Why not pumping? Pump shaft worn out
5. Why worn out? No screen, scrap was let in

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 Push vs. Pull

Push System
 Material is pushed downstream and inventory
builds regardless of resource availability
 Strong emphasis on production first

 Stock points and additional inventory can

overflow with parts and raw materials

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 Traditional Push Production System

Big purchase • Huge lot sizes Big “pushes”

shipments w/ • Lots of inventory of finished
• “Push” material to
lower per goods to
unit shipping
next stage warehouse or
cost customers

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 Pull vs. Push

Pull System
 The customer starts the production process by
pulling production when it is needed
 Material is moved to workstations as it is
needed
 Stock points are kept at a minimum

 Waste is MINIMIZED

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 Pull Production System

Smaller Goods are

• Smaller lots
shipments w/ “pulled” by
• Faster setups
• Less inventory
minimal / demand out
no inventory of the plant
holding cost

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 Necessary Conditions For Pull
1. Planning and Control Responsibility
2. Producing to Meet Demand
3. Reduce In-Process Inventories
4. Preventative Maintenance
5. Quality Assurance
6. Setup Times Must be Small
7. Linking of All Operations
8. Production Plans and Schedules Must Be
Uniform
9. Develop Cooperative Attitudes and Teamwork
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 Achieving Pull Production
Pull System as Reorder Point (ROP) System
ROP  D( LT )  SS
D = demand (consumption rate)
LT = lead time (elapsed time btwn order and
replenishment
LT  P  C
P = production time
C = conveyance time (time to convey order to
upstream process, plus time to move materials to the
downstream operation
SS = safety stock (number of parts)
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 Achieving Pull Production
Standard-Sized Containers
 If Q = the capacity of a standard container, then
ROP as expressed in terms of the number of
containers is K, or the maximum number of
completely full containers in a buffer
D( P  C )
K
Q
Container Size
 Container should hold about 10% of the daily
demand

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 Kanban

Kanban card shows typical production

quantity
Derived from two-bin inventory system
Maintains pull production system
A production kanban authorized production
A withdrawal kanban authorizes material
handling

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 Kanban Pre-Conditions
Point of use
inclusion (all parts Level production
on the assembly line)

There are four

pre-conditions for
the successful
implementation of
Kanban
Quick Changeover Stabilized processes
procedures

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 Kanban

Kanban means “signboard”

 Kanban is a signal used to communicate
production cues in a pull production system
Production Withdrawal
Kanban Kanban
A

B
Machine Center Assembly Line
Storage

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 Sample Kanban Card

Part No.: 6934

Description: Servo motor

Box capacity: 30
From: Box type: AF To:
Assembly Issue No.: 06 Station
3 D-7

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 Sample Kanban Card

Market Address Kanban Number Line-Side Address

<<Market_Address>><<Kanban_Number>> <<Line_Side_Address>>

Part Number Route

<<Part Number>> <<Route>>

Bar Code Area

Part Description Dock Code
<<Part Number>> <<Dock Code>>
Supplier Code Quantity Serial Number

<<Supplier Code >> <<Quantity>>

Comment:
<<Comment>>

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 Conveyance Kanbans
A conveyance kanban, or C-kanban,
authorizes containers to move from an
upstream, outbound buffer to a downstream,
inbound buffer
Kc = number of C-kanbans
D(C )
Kc 
Q
C = total time between when workers remove a C-kanban
from a full container at the inbound buffer and when
they remove a C-kanban from the next full container
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 Production Kanbans

P-kanban is used to authorize production

parts to assemblies
Kp = number of P-kanbans
D( P)
Kp 
Q
P = total time elapsed from when workers or mat’l
handlers remove the P-kanban from a full container and
post it at the outbound buffer until the time they
remove the P-kanban from the next full container

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 1 & 2-Card Kanban Systems

1-card systems use only C-kanbans

2-card systems use both C-kanbans and P-

kanbans

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 DISCUSSION

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