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LOGO
JUST-IN- TIME
Presented by:-
Sebastian Jacobs
Rahul Passi
Monica Chopra
Shilpa Mehra www.company.com
OVERVIEW
• Learning objective
• History
• Meaning
• Concept
• Characteristics & Advantages
• Practical example
• How it works?
LEARNING OBJECTIVES
Inventory
level
Inventory
level
Process Process
Scrap Scrap
downtim downtim
Setup Setup Quality e
Quality e time
time problem problem
s s
Late Late
deliveries deliveries
LOWERING INVENTORY
REDUCES WASTE
Unreliable Capacity
Scrap
Vendors Imbalances
Reducing inventory reveals
problems so they can be solved.
WIP
Unreliable Capacity
Scrap
Vendors Imbalances
Reducing inventory reveals
problems so they can be solved.
• Preventive maintenance
• Continous improvement
ADVANTAGES OF USING JIT
• Overall savings.
• Efficiency is increased.
• Overproduction
• Waiting
• Transportation
• Inefficient processing
• Inventory
• Unnecessary motion
• Product defects
JIT REDUCED WASTE AT Hewlett-Packard
Suppliers
Employee
Layout
Empowerment
JIT
Quality Inventory
Preventive
Scheduling
Maintenance
STREAMLINED PRODUCTION
Traditional Flow Production Process
(stream of water)
Suppliers
Customers
Inventory (stagnant
Flow with JIT ponds) Material
(water in
Suppliers stream)
Customers
PRACTICAL EXAMPLES
Two-week production forecast
A ™
B
vs. C
Typical US
automaker
plant
50 % 25 % 25 %
Accounting for
JIT and accounting 11/03/2009
Managers II
PRACTICAL EXAMPLES
Typical US automaker
A B C
5
Week 1 days
Week 2 2½ 2½
days days
Accounting for
JIT and accounting 11/03/2009
Managers II
PRACTICAL EXAMPLES
Toyota JIT plant
A B C
A
Week 1
10
days
Week 2 C B
Accounting for
JIT and accounting 11/03/2009
Managers II
PRACTICAL EXAMPLES
Typical US automaker
Disadvantages of the typical design
Week 2
BB BB
• Late identification of defects BB CC CC
BB BB CC CC CC
Accounting for
JIT and accounting 11/03/2009
Managers II
PRACTICAL EXAMPLES
Toyota JIT plant
Advantages of the JIT design
• Greater flexibility
• Mixed production
AB AB AB AB AB
Week 1 • No disruptions
AC AC AC AC AC
• Low setups and little adjustment for workers
• Less inventory capacity needed (WIP and FG)
Week 2
AB AB
• Immediate identification of defects AB AB AB
AC AC AC AC AC
Accounting for
JIT and accounting 11/03/2009
Managers II
PRACTICAL EXAMPLES
Porsche’s Stuttgart plant
™
Production time of 911
120
in hours
50 %
60
3
> 50 %
Source: Garrison et. al.: Managerial Accounting, 11th edition, 2006, McGraw-Hill.
Accounting for
JIT and accounting 11/03/2009
Managers II
LAYOUT
• JIT objective: Reduce movement of people and
material
– Movement is waste!
• JIT requires
– Work cells for product families
– Moveable or changeable machines
– Short distances
– Little space for inventory
– Delivery directly to work areas
WORK CELL versus PROCESS LAYOUT
REDUCING LOT SIZES
Lot size = 2
Lot 1 Lot 2 Lot 3 Lot 4 Lot 5
UNLESS SETUP COSTS ARE REDUCED
Cost
Setup Cost
New Original
optimal lot optimal
Lot Size
size lot size
SMALL VERSUS LARGE LOTS
JIT produces same amount in same
JIT Small Lots time if setup times are lowered
A A B B B C A A B B B C
Time
Small lots also increase flexibility to meet
customer demands
Large-Lot Approach
A A A A B B B B B B C C
Time
KANBAN
• Japanese word for card
– Pronounced ‘kahn-bahn’ (not ‘can-ban’)
• Authorizes production from downstream
operations
– ‘Pulls’ material through plant
• May be a card, flag, verbal signal etc.
• Used often with fixed-size containers
– Add or remove containers to change production
rate
DIAGRAM OF OUTBOUND STOCKPOINT
Minimizing Waste: Kanban Production
Control Systems
Once the Production kanban is This puts the
received, the Machine Center Withdrawal system back
produces a unit to replace the kanban were it was
one taken by the Assembly Line before the item
people in the first place was pulled
Storage Storage
Machine Part A Part A Assembly
Center
Line
Production kanban
Material Flow
The process begins by the Assembly Line
people pulling Part A from Storage Card (signal) Flow
IMPLEMENTATION PROBLEMS
• Worker resistance
• Lack of communication