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Just-In-Time Manufacturing. David Comita Arielle Herold Jaslyn Moore Shanelle Williamson. Introduction.
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Just-In-Time Manufacturing David Comita Arielle Herold Jaslyn Moore Shanelle Williamson
Introduction Just-In-Time or JIT Manufacturing is a management philosophy that improves businesses by decreasing inventory and the costs associated with it. JIT focuses on constant improvement of manufacturing’s organizations return on investment, quality and efficiency.
Outline • History • Philosophy • JITs approach to Manufacturing • Strengths • Weaknesses • Real Life Examples
History • JIT was first developed within Toyota manufacturing plants by TaiichiOhno during the early 1970s. • “The oil embargo probably triggered his theory, the program was intended to avoid wastes, reduce inventories and increase production efficiency in order to maintain Toyota’s competitive edge” (Lorefice).
History • “JIT is a Japanese management philosophy which has be applied in practice since the early 1970s in many Japanese manufacturing organizations. It was first developed and perfected within the Toyota manufacturing plants by TaiichiOhno as a means of meeting consumer demands with minimum delays. • “Toyota realized that JIT would only be successful if every individual within the organization was involved and committed to it, if the plant and processes were arranged for maximum output and efficiency, and if quality and production programs were scheduled to meet demands exactly” (JIT Just-in-Time manufacturing).
Philosophy • A management philosophy that continuously focuses on integrating and streamlining the manufacturing system into the simplest process possible. • A devotion to the process of continuously striving to minimize elements in manufacturing system that restrain productivity.
Goal#1 :Design for optimum quality and cost and ease of manufacturing • Design for customer satisfaction • Reduce the cost of manufacturing. • Design products for manufacturability • Use only proven technology. • Use design standardization • Simplify product design • Design for ease of construction and assembly • Minimized design and production cost • Design for product strength
Application of Goal #1 • Monitor customers request and problems • Use production and supplier involvement in the design process • Have a formal design acceptance based on production goals • Set formal goals on production performance • Minimize the cost of labor, materials and equipment in production
Goal#2:Minimized the resources expanded to produce a product • Integrate and optimize every step in manufacturing process • Build product to specification • Use work cell and pull production process • Locate and remove source of excess inventory • Set manufacturing standards at zero defects • Have each function be responsive for its own quality
Application of Goal#2 • Eliminate idleness in production system • Establish goals requiring continuous improvement in the manufacturing system • Remove all forms of gate inspection from the production system • Establish production responsibility for product quality
Goal#3:Be responsive to the customer • Provided customer with he or she wants • Develop manufacturing flexibility • Design product to meet costumer requirements • Reduce manufacturing lead time • Provide product on schedule • Provide product at the expected quality level
Application of Goal #3 • Continually monitor customer satisfaction • Have engineers meet with customers • Use kanban system for triggering production requirements • Eliminate all unnecessary inventory • Reduce or eliminate lead time from: supplies, overhead processes and manufacturing functions • Use flexible production processes and equipment • Train employees to operate a wide variety of process
Goal#4:Develop and trust open relationship with both suppliers and customers • Gain supplier and customer confidence in the company’s ability to maintain commitments • Develop processes and procedure necessary to commitments. • Use open kimono policy to develop supplier and costumer confidence • Use long-term contracts
Application to Goal#4 • Stabilize the supplier base • Fail-safe the production process • Give employees the authority to stop the production process (if needed) • Set a company wide policy of doing the job right • Deliver quality product on schedule.
Goal#5: Develop the commitment with each function and employee to improve the total manufacturing system • Do each job right every time • Use an open approach to planning and implementing a JIT system • Focus on prevention of problems rather than the resolution of problem after they occur • Continuously educate employees with regard to the need of supplier, costumers and the production process
Application of Goal#5 • Design production systems with intent to prevent problems • Establish a company wide defect prevention • Program • Use total quality control and statistical process control techniques.
Weakness • Requires considerable discipline on the part of every worker and supervisor; e.g. • Don’t work if no Kanban • Don’t lose Kanbans • Requires “pushing” for long lead-time raw materials and components (or huge inventories) • “Entropy”; i.e., explosion of WIP and Finished Goods for Products with Lots of Variety
Strengths • Shop floor makes and implements decision’s in response to the “Pull” on the system • Status of shop floor easy for management to see • Designed to respond quickly to: • Past events • Future events (if carefully planned in advance by management)
