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JIT is a production philosophy. JIT uses the pull method of scheduling material flow. Kanban- visual record (1950) Where Kan means Card Ban means signal To produce goods and services as needed. JIT systems are known by many different names including zero inventory, synchronous manufacturing, lean production, stockless production, material as needed and continuous flow manufacturing.
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Basically production can be considered in two categories: Produce on demand, pull system. A pull system uses bottom up demand which it is driven by the consumption rate of the parts in the production process. More materials in the production line when they are needed. Pull method in which customer demand activates production of the item manufacturer Pull customer b) Push method. In which the production of the item begins in advance of customer need. With this method management schedules the receipt of all materials and authorizes the start of production. Manufacturer push customer JIT refers to the production and supply of the required number of parts/products when needed. Workers perform the required operation on the material/work part drawn from the preceding work station at the necessary time with the use of a
Withdrawl Kanban
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OBJECTIVES OF JIT
A JIT system of production management aims of achieving the following major objectives or ideas.
Zero set up times Zero inventory Zero breakdown Zero defects Zero waiting times for material/component Zero waste of any kind
CHARACTERISTICS OF JIT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. People involvement Team work Discipline TQM Pull method of material flow Small lot sizes- variety of products Short set up times Uniform workstation loads Standardized components and work methods Close supplier ties Flexible work force Product focus Automated production Preventive maintenance
Set up times
Operating control
Small lots Zero inventory objective Last stage first Low Low and frequent
Decentralized
Long runs Stock needed for flexibility First stage first High High and infrequent Centralized Mono-skilled Managed by quality control unit
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a) b) c) d) e) f)
PREVENTIVE MAINTENANCE
As the inventory levels are reduced in a JIT implementation unreliable machines become more of problem. The reduction in the buffer stocks means that if a machine should break down, subsequent machines quickly become started of the work. In order to prevent this happening the JIT implementation includes a preventive maintenance program to keep insure high process reliability in keeping with other aspects of JIT.
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Cope with fundamental extent problems, capacity, bottleneck, machine breakdown. Eliminate waste in all forms- inspection, transport, wasting, inventory. Strive for simplicity- simple unidirectional and smooth flow of parts and products. Create system to identify and resolve problems at source.
ELEMENTS OF JIT
There are six different internally focused elements and one externally focused element. i) The first internally focused element is the just-in time philosophy itself. ii) Quality at the source. there are three manufacturing engineering elements: iii) Uniform plant load. iv) Over-lapping operations (machine cells or group technology). v) Minimum setup time. vi) Type of control system called, variously, a pull system, Kanban, or linking operations.
JIT philosophy
Flow
Employee involvement
Quality
Overlapping operations
pull system
JIT purchasing
KEYS TO SUCCESSFUL JIT IMPLEMENTATION PRODUCTION SMOOTH 1. Establish and level the MPs with uniform plant loading.
create a uniform load on all work centers through constant daily production, establish freeze windows to prevent changes in the production plan for some period of time and mixed model assembly (produce roughly the same mix of products everyday) using a repeating sequence if several products are produced on the same line meet demand fluctuations through end items inventory rather through fluctuations in production level. Benefits: a) Learning curve improvements b) Increased mix flexibility c) Reduced inventory d) Shorter lead times e) Quality improvements.
2. Reduced lot sizes. Aim for reducing setup times, allows economical products of smaller lots; close cooperation with supplies is necessary to achieve reductions in order lot sizes for purchased item since this will require more frequent deliveries. 3. Preventive maintenance. Use machine and worker idle time to maintain equipment and prevent breakdowns. 4. Flexibility workforce. Worker should be trained to use several machines to perform maintenance tasks and to perform quality inspections. 5. Require supplier quality assurance.
Require supplier quality assurance and a zero defect quality program, errors leading to defects item must be eliminated since there are no buffers of excess parts.
A quality of source (JIDOKA) program must be implemented to give workers, the personal responsibility for the quality of the work they do, and the authority to stop production when something goes wrong.
6. Reduce or eliminate setup time. 7. Zero inventory 8. Systems to work on. 9. Small lot size (single unit).
Control system such as Kanban (cards)system to convey parts between work stations in small quantity (ideally one unit at a time). In largest sense, JIT is not the something as a Kanban system is not required to implement a LKanban system and the two concepts are frequently equated with one another.
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Just in time production (inventory management). Maintain minimum inventory level and small lot sizes and make no allowance for contingency. Uniform plant loading (level production schedule). Setup a firm production plan with the output rate is frozen for the nearest future. Kanban system (production control tool). Minimized setup times (work method improvement). Separate setup times into internal and external setup procedures. Apply the time and motion studies and practice.
5. Work in process inventories: eliminate by reducing setup times, increasing production rates and better coordination of production rates between work stations. 6. Motion and effort: improve productivity and quality by eliminating unnecessary human motions, make necessary motions more efficient, mechanize, then automate. 7. Defective products: eliminate defects and inspection. Make perfect products.
4. Understanding the tasks of implementation. JIT is not a soft or easy technique. 5. long/short period of implementation. This problem requires a balanced approach if the implementation period is long, loss of motivation and enthusiasm among the workers may be engendered. 6. For dealing with customer schedule changes JIT links with customers should be established and fostered. 7. JIT links with vendors should be fostered along with the lines of partner in profit concept. 8. Shortage of critical parts. This may require recourse to contingency plans or measures. 9. Workers fears and anxieties concerning their jobs security and status need to be alleged. 10. Inability to reduce setup time. This may require engineering research to be undertaken intentionally or through R&D firms.
11. The operation of a JIT flow line relies on what process improvement and control improvements. They need to be integrated .the problem may be investigated by a study team of industrial engineering and experienced workers/ operators. 12. This can have serious implication for the success of JIT program in near future. The primary requirements here is the regular contributions of the JIT education program. This needs to be critically supplemented by establishing the quality circle or productivity teams of workers.