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Definition
JIT is a manufacturing system whose goal is to

optimize processes and procedure by continuously pursuing waste reduction It is both a philosophy and a set of methods for manufacturing. Although it has no single, agreedupon definition ,JIT emphasizes waste reduction, total quality control, and devotion to the customer.

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Evolution of JIT
The history of Japan since world war II is the history of a developing economy, especially manufacturing. The Japanese economy was also ruined and faced the challenge of transition from wartime to a peacetime economy with very resources. This scarcity of resources was a key factor in the evolution of the Just-In-Time philosophy.

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The Seven Wastages

Shigeo Shingo, a recognized JIT authority and engineer at the Toyota Motor Company identifies seven wastes as being the targets of continuous improvement in production process. By attending to these wastes, improvement is achieved.

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Contd
Waste of Overproduction
Waste of Waiting Waste of Transportation Waste of Processing itself Waste of Stocks Waste of Motion Waste of Making Defective Products

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Japanese Manufacturing Techniques

Produce what the customer desires
Produce products only at the rate the customer wants

them Produce with perfect quality Produce by methods that allow people to develop

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Contd
Produce with no waste of labour, material,

or equipment; every move has a purpose so there is zero idle inventory Produce instantaneously with zero unnecessary lead time

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Minimizing Waste: Group Technology (Part 1)

Note how the flow lines are going back and forth
Using Departmental Specialization for plant layout can cause a

lot of unnecessary material movement

Saw Saw Saw Grinder Grinder

Heat Treat

Lathe

Lathe

Lathe

Press

Press

Press

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Minimizing Waste: Group Technology (Part 2)

Revising by using Group Technology Cells can reduce movement and

improve product flow

Grinder Saw Lathe

Lathe

Press

Heat Treat

Grinder Saw Lathe

Lathe

Press

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Minimizing Waste: Just-In-Time Production

WHAT IT IS Management philosophy
Pull system though the plant Hydraulic Push Systems

WHAT IT DOES Attacks waste

Exposes problems and bottlenecks Achieves streamlined production

WHAT IT REQUIRES

WHAT IT ASSUMES Stable environment

Employee participation
Industrial engineering/basics Continuing improvement Total quality control Small lot sizes
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JIT Implementation Requirements: Design Flow Process

Link operations Balance workstation capacities Redesign layout for optimum flow

Emphasize preventive maintenance

Reduce lot sizes

Reduce setup/changeover time

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JIT Implementation Requirements: Total Quality Control

Worker responsibility SQC in place Enforce compliance Fail-safe methods (poka-yoke)

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JIT Implementation Requirements: Work with Vendors

Reduce lead times Frequent deliveries

Project usage requirements

Clear Quality expectations

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JIT Implementation Requirements: Reduce Inventory More

Look for other areas to reduced materials Minimize Stores Minimize Transit Carousels Conveyors

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JIT Implementation Requirements: Improve Product Design

Standard produce configuration Standardize and reduce number of parts

Align Process design with product design

Quality expectations

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JIT Implementation Requirements: Measure Performance

Emphasize improvement Track trends

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JIT in Services (Examples)

Organize Problem-Solving Groups Upgrade Housekeeping Upgrade Quality Clarify Process Flows Revise Equipment and Process Technologies

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JIT in Services (Examples)

Level the Facility Load Eliminate Unnecessary Activities Reorganize Physical Configuration Introduce Demand-Pull Scheduling Develop Supplier Networks

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