CH9 JIT (1)
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Transcript of CH9 JIT (1)
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Just-in-Time SystemsJust-in-Time Systems
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Topics to be CoveredTopics to be Covered
Review of JIT & WasteObjectives of JIT
JIT Principles
Characteristics of jit
Benefit
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What is JIT?What is JIT?
a corporate system designed toproduce output within the minimum
lead time and at the lowest total cost bycontinuously identifying and eliminatingall forms of corporate waste andvariance.
a corporate strategy
a philosophy
Focus of JIT:
variance & waste
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Seven Basic Types ofSeven Basic Types of
WasteWaste
Transportation waste
Process Waste
Inventory WasteWaste of motion
Waste from product defects
Waiting timeOverproduction
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Common Causes of WasteCommon Causes of Waste
Layout (distance)
Long setup time
Incapable
processesPoor
maintenance
Poor workmethods
Lack of training
Inconsistentperformancemeasures
Ineffectiveproductionplanning
Lack ofworkplaceorganization
Poor supplyquality/reliability
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Objective of JITObjective of JIT
Produce only the products thecustomer wants.
Produce products only at the ratethat the customer wants them.
Produce with perfect quality
Produce with minimum lead time.
Produce products with only thosefeatures the customer wants.
Faster reaction to demand change
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ObjectivesObjectives
Produce with no waste of labor,material or equipment -- everymovement must have a purpose
so that there is zero idleinventory.
Produce with methods that allow
for the development of people
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JIT PrinciplesJIT Principles
Create flow production
one piece flow
machines in order of processes
small and inexpensiveequipment
U cell layout, counterclockwise
multi-process handling
workers
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JIT Principles - Slide 2JIT Principles - Slide 2
Establish TAKT time
rate at which the customerbuys a product
Build Pull Product
use of kanban system
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Benefits
Inventory costs are reduced
Material flow improvementReduced production lead time
Product quality is improvea and cost
of scrap is reduced
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Points to be considerd to made jiteffective
Multiple skill
Stablize master plan schedule
Small EOQ
Defect free material
Items should be present at time
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JIT TacticsJIT Tactics
Single MinuteExchange of Dies(SMED)
Statistical Process
ControlUse of standard
containersDoable stable
schedules with
adequate visibilityTAKT-Time5-S ProgramKaizen Event
Visual control
Flexible workers
Tools at the point ofneed
Product redesign
Group Technology
Total Productive
Maintenance
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Balanced ProductionBalanced Production
Three elements
TAKT time
Work sequence Standard WIP
Objective
Build at rate that the customer wantswork
Balance the system to maximize
efficiency at this rate
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SMEDSMED
Setup reductionElements
Internal Setup setup while machine idle
External Setup
setup while machine busy
Adjustment
run-ins, calibration
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Limitations of JITLimitations of JIT
Preconditions to JIT trust must be present
labor/management
suppliers/consumers recognition of processes
familiarity with problem solving
quality at the source
agreement over value and waste
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Limitations of JITLimitations of JIT
Right Settings applicable in growth to maturity
phases of
Product Life Cycle
standard product
Steinway and JIT
standard/fixed pay-rate
problems with piece-rate schemeUniversal agreement that change
needed
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Theoretical Benefits of JITTheoretical Benefits of JIT
Unpleasantsurprises
eliminatedLess
computerization
visual control
Improved quality
WIP reduced
Better
communications
Less pressure onreceiving docks and
incoming inspectionareas
Lower costs
Change in attitude
Defects aretreasures
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The 5-S ProgramThe 5-S Program
Seiri
segregate and discard
get rid of what is not neededSeiton
arrange and identify for ease of use
a place foreverything and everythingin its place
Seiso
Clean Daily
clean work place enhances quality
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The 5-S ProgramThe 5-S Program
Seiketsu
Revisit frequently
revisit the first 3 steps to maintainworkplace safety and effectiveness
Shitsuki
Motivate to sustain promote adherence through visual
performance measurement tools