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Just in Time

Just-in-Time and Lean Systems aim to eliminate waste through continuous improvement. JIT receives goods only as needed to decrease inventory waste. It was developed by Toyota in the 1970s with goals of zero defects, full workforce capability, and making only what is needed. Elements include reducing setup times and lot sizes to decrease lead times. Lean systems use small lot pull production and preventive maintenance to achieve uniform workloads and flexible workflows with close supplier relationships. Cellular manufacturing arranges equipment by process sequence for efficient one-piece flow. Kanban scheduling uses cards to communicate production quantities and reduce inventory levels. Benefits include lower costs, less waste, and better quality.

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Divya Nair
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30 views

Just in Time

Just-in-Time and Lean Systems aim to eliminate waste through continuous improvement. JIT receives goods only as needed to decrease inventory waste. It was developed by Toyota in the 1970s with goals of zero defects, full workforce capability, and making only what is needed. Elements include reducing setup times and lot sizes to decrease lead times. Lean systems use small lot pull production and preventive maintenance to achieve uniform workloads and flexible workflows with close supplier relationships. Cellular manufacturing arranges equipment by process sequence for efficient one-piece flow. Kanban scheduling uses cards to communicate production quantities and reduce inventory levels. Benefits include lower costs, less waste, and better quality.

Uploaded by

Divya Nair
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Just-in-Time and Lean Systems

4/21/12

Just-in-Time
v Its a philosophy of manufacturing based on

planned elimination of all waste & continuous improvement of productivity.

v JIT is an approach that seeks to eliminate all

sources of waste in production activities by providing the right part at the right place at the right time.
v An inventorystrategy companies employ to

increase efficiency and decrease waste 4/21/12 byreceivinggoods only as they are needed

JIT-Philosophies
v JIT system was developed at the Toyota Motor

company in Japan in mid 1970s by Taiichi Ohno and his several associates.
v Try to achieve Zero defects. v Utilizing the full capability of the workforce. v Making only "what is needed, when it is needed,

and 4/21/12 in

the amount needed!".

Elements Of JIT
v Reduce or eliminate setup times v Reduce lot sizes v Reduce lead times v Flexible work force v Require supplier quality assurance and implement a zero

defects quality program


v Smalllot (single unit) conveyance v Preventive maintenance
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Characteristics of Lean System


1. Pull Method Of Material Flow: A method

in which customer demand activates production of the item. Fast food workers using the pull system to serve their customers. This method allows closer control of inventory and production at the workstation.

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2.Small Lot Sizes: Users of JIT systems maintain inventory with lot sizes that are as small as possible. Small lot sizes reduces cycle inventory. 3.Uniform Workstation loads: The JIT system works best if the daily load on individual workstations is relatively uniform. Uniform loads can be achieved by assembling the same type and number of units each day.
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4. Close Supplied Ties: Because JIT systems operate with very low levels of inventory, close relationships with suppliers are necessary. Stock shipments must be frequent, have short lead times, arrive on schedule, and be of high quality. 5.Flexible Workforce: Workers in flexible workforce can be trained to perform more than one job.
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6.Preventive maintenance: preventive maintenance can reduce the frequency and duration of machine downtime. After performing routine maintenance activities, the technician can test other parts that might need to be replaced.

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CELLULAR MANUFACTURING

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What Is Cellular Manufacturing?


A lean manufacturing approach that helps

companies build a variety of products with as little waste as possible


Equipment and workstations arranged in a

sequence that supports smooth material flow through the process, with minimal transport or delay

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One Piece Flow/Single Piece Flow


One-piece flow is

the state that exists when products move through a manufacturing process one unit at a time.

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One-Piece Flow Vs. Large-Lot Production

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Understanding Processes and Operations

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Benefits of Cellular Manufacturing


Cut costly transport and delay from the

manufacturing process

Serves customer needs Gives an earlier return on the investment in

the product
Saves space in the factory Can be used for other value-adding purposes
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How Cellular Manufacturing Helps You?


Makes daily production work go smoother by:
Removing Reducing Reducing

clutter of excess WIP inventory

transport and unnecessary handling

walking required to complete processes causes of defects and machine problems that cause delays

Addressing

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The Kanban System

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Kanban means cards or visible records in Japanese, which are used to communicate within, to and from a work centre. It is a scheduling system that helps determine what to produce, when to produce it, and how much to produce. There are two kinds of Kanban:
Production Kanban
4/21/12 Withdrawal

Kanban

Container is emptied at work centre B

The full container and the Withdrawal Card are moved to Centre B

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The empty container is left at workstation A

Workin g of Kanba n Syste m

The empty container and its Withdrawal card is taken back to Centre A

The production card is placed in the Kanban Receiving Post at Centre A

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Working of Kanban System

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Calculation of Number of Kanban Required

N = number of containers D = demand rate at the withdraw station T = lead time from supply station C = container size

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Benefits of Kanban
Reduced inventory level Less confusion over sequence of activities Less obsolescence of inventories while in storage Smaller floor space requirements for storing inventory Reduced lead time Improved quality
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Higher employee productivity

Benefits of JIT
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q Reduction in inventories q Improved quality q Shorter lead times q Lower production costs

q Increased productivity q Increased machine utilization


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Implementing JIT
Starts with a company shared vision of

where it is and where it wants to go


Management needs to create the right

atmosphere
Implementation needs a designated

Champion
Implement the sequence of following steps
Make quality improvements
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Reorganize workplace

Contd
Reduce lot sizes & lead times Implement layout changes

Cellular manufacturing & close proximity

Switch to pull production Develop relationship with suppliers

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Thank You
Group 8: Abhilash (151) Snehlata (144)
4/21/12

Harsh (146)

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