JUST IN TIME SYSTEMS

1. JUST IN TIME SYSTEMS Merve Sezen GÜLER 2010503029 Industrial Engineering Department, Dokuz Eylul University, Turkey Just-In-Time Systems

2. Learningobjectives : • Understanding the theory behind Just-In-Time • Understanding the advantages of using Just-In-Time • Just-In-Time production systems Just-In-Time Systems

3. What is Just-In-Time ? • Just-In-Time (JIT) is an easy concept • to understand. • If you think about someone's journey to work, • they could leave the house just-in-time to get • to the bus station, just-in-time to catch the bus, • which would get them to their place of work • just-in-time, allowing them to be at their desk • just-in-time to start work. Just-In-Time Systems

4. What is Just-In-Time ? • Just-In-Time (JIT) is a collection of techniques used to improve operations. • JITis a manufacturing philosophy which eliminates waste associated with time, labour and storage space. • In engineering, using the just-in-time theory would allow the components that are needed to produce a product to be delivered to the worker, just-in-time. • The products can then be made available for the customers just-in-time. Just-In-Time Systems

5. What is Just-In-Time ? What is Just-In-Time ? • This process allows for all types of stock, including materials and finished products, to be eliminated. • Implementing a just-in-time structure can mean a company is adopting a lean production system. Just-In-Time Systems

6. Basics of the JIT; • The company produces only what is needed, when it is needed and in the quantity that is needed. • The company produces only what the customer request, to actual orders, not to forecast. • JIT can also be defined as producing the necessary units, with the required quality, in the necessary quantities, at the last safe moment. • It means that company can manage with their own resources and allocate them very easily. Just-In-Time Systems

7. Why use Just-In-Time? • There are several aspects in engineering processes that are often deemed as wasteful, which can be eliminated using a JIT approach. • These include: • Time spent waiting • Over production • Inventory Just-In-Time Systems

8. Figure 1 Work in process inventory level hides the problems inventory Unreliable Vendors Capacity Imbalances Scrap • Inventory is like water in a stream • Rocks are like problems Just-In-Time Systems

9. Figure 2 Unreliable Vendors Capacity Imbalances Scrap • Reducing inventory makes problems very visible • Reducing inventory reveals problems to be corrected. Just-In-Time Systems

10. JIT SYSTEMS; • Kanban • JIDOKA • SMED (Single Minute Exchange of Die) • The 5-S System Just-In-Time Systems

11. KANBAN Production Control Systems • Kanban is a Japanese word for card. • Kanban is a method for implementing JIT. • In order to produce, you need both; - material to work on - an avaliable Kanban. • Each work station has a fixed kanbans. Just-In-Time Systems

12. KANBAN Production Control Systems How does the Kanban system work? Just-In-Time Systems

13. KANBAN Production Control Systems Flow of work 2 3 • Worker 2 finishes a part, outbound moves over • 2 has a green tag available, so 2 gets another part to work on: • 2 takes off 1’s pink tag giving it back to 1, and • puts on his green tag and moves it into position.

14. KANBAN Production Control Systems Flow of work 2 3 • When 3 finishes a part, • Finished parts move over one spot • He has to have a blue tag available to put on, • He gets a part from 2’s outbound pile, • And gives the green back to 2 • 3’s production will be taken by 4, offstage right. • Tag goes back into 3’s bin

15. KANBAN Production Control Systems 2 3 • Blue finishes his part next. • But 4 hasn’t freed up any of the blue kanbans, so there is nothing for 3 to work on now. • 3 could maintain his machine, or see if 4 needs help 2 3

16. JIDOKA (Autonomation) “Automation with human intelligence” = AUTONOMATION JI DOU KA JIDOKA Just-In-Time Systems

17. JIDOKA (Autonomation) • Jidoka is providing machines and operators the ability to detect when an abnormal condition has occurred and immediately stop work. • Jidoka is one of the two pillars of the Toyota Production System along with just-in-time. • Jidoka is sometimes called autonomation, meaning “automation with human intelligence”. Just-In-Time Systems

18. JIDOKA (Autonomation) • Jidoka helps to detect a problem earlier. • Jidoka avoids the spread of bad practices. • No defective products produced. • There is a tremendous improvement in productivity. Just-In-Time Systems

19. JIDOKA (Autonomation) Automation detects a problem A problem interrupt the workflow Figure 3 Concept of JIDOKA The problem is fixed. Work is Stopped. Improvements are incorporated into the workflow.

20. Reducing the setup time is an important precondition for increasing the flexibility and the capacity of a production line. • SMED is a method used to analyse and reduce setup times. • Setups that took hours could be reduced to minutes. SMED Single Minute Exchange of Die Just-In-Time Systems

21. SMED Single Minute Exchange of Die The SMED method consists of 3 steps ; • Seperate internal and external activities. • Convert internal activities into external activities. • Eliminate and/or reduce all activities (Internal and external) External : Activities while machine is stopped. Internal : Activities while machine is running. Just-In-Time Systems

22. The 5-S system is developed in Japan. • The 5-S system is a series of activities designed to improve workplace organization and standardization. • A well organised workplace motivates people. Efficiency and quality increase. The 5-S SYSTEM Workplace organization and standardization Just-In-Time Systems

23. The 5-S SYSTEM Workplace organization and standardization • All of these 5 activities begin with letter ‘S’. They include; • Seiri (Sort) :Remove all unneeded items. • Seiton (Set In Order) :Organize, identify and arrange everything in a work area / space • Seiso (Shine) :Clean everything, use cleaning as inspection. • Seiketsu (Standardize) : Implement visual displays and controls • Shitsuke (Sustain) : Maintaining what has already been achieved accomplished Just-In-Time Systems

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