JAPANESE TECHNOLOGY, JUST IN TIME APPROACH,

1. Quality and Reliability Engineering
(171906)
PROF. MAYUR S. MODI
MECHANICAL ENGINEERING DEPARTMENT
SSASIT,SURAT
1 PROF. MAYUR MODI

2. As a Manufacturing Leader...
You will play a
critical role in the
management and
control of the
companies critical
information.

3. The Problem of
Manufacturing…
Getting the right material and physical
resources together at the right place
and at the right time to meet the
customer’s requirements.
Desired features, On time delivery, High
Quality, at the best price…

4. Breaking down the problem…
Getting the material
needed…
Having enough
inventory of material
to support
production
Not having too much
inventory and extra
costs…

5. Manufacturing and CIM
Systems…
Where the action is!

6. JUST IN TIME:JUST IN TIME:
Only what is needed, nothingOnly what is needed, nothing
more...more...
To haveTo have onlyonly the right materials, partsthe right materials, parts
and products in the right place at theand products in the right place at the
right time.right time.

7. Just-In-Time (JIT) manufacturing distances itself
from the competition because no large capital
outlays are required.
Other methods promote complexity, large
overheads, automation, and other "state-of-
the-art" technologies, while JIT advocates
simplifying and streamlining the existing
manufacturing process.

8. JUST-IN-TIME: A DEFINITION
Organizes the production process so that parts are
available when they are needed
Uses a systems approach to develop and operate
a manufacturing system
A method for optimizing processes that involves
continual reduction of waste

9. JIT is a concept business philosophy and the
process of thinking, working, and managing to
eliminate waste.

10. PHILOSOPHY OF JUST-IN-TIME
JIT originated in Japan at Toyota Motor Co,
fueled by a need to survive the devastation post
WWII
JIT gained worldwide prominence in the 1970s
Often termed “Lean Production” or “Lean
Systems”
Broad view that entire organization has the same
goal - to serve customers

11. Fundamentals of JIT
Design Products for Economical Production.
Change Plant Layouts to Facilitate “ Flow of
Manufacturing”
Institute Worker involvement Programmme
Improved data Accuracy.
Reduce Paper Work.
Reduce Scrap.
Reduce Inventories.
Strive for continuous Improvements.

12. Integrating JIT with Other Elements of
Production System

15. What To Expect ?
While the prevailing view of JIT is that of an
Inventory control system, it is much more. JIT
is an operational philosophy which incorporates
an improved inventory control system in
conjunction with other systems, such as:
• A set-up time improvement system.
• A maintenance improvement system.
• A quality improvement system.
• A productivity improvement system.

16. A properly implemented JIT system should:
• Produce products customers want.
• Produce products only at the rate that customers want them.
• Produce with perfect quality.
• Produce instantly with zero unnecessary lead time.
• Produce with no waste of labour, material, or equipment.
Every move has a purpose and there is no idle inventory.

17. An overview of JIT literature suggests that the steps
or elements of the implementation process generally
• Reductions in set-up time.
• Utilization of a formal preventive maintenance program.
• Utilization of quality circles.
• Utilization of cellular manufacturing techniques.
• Cross-training of employees.
• Quality certification of suppliers.
• Reductions in vendor lead time.
• Reductions in lot sizes.
• Sole sourcing.
• Presence of one who "championed the cause of JIT within the
firm.

18. Objective of JIT
JIT Manufacturing tries to smooth the flow of materials
from the suppliers to the customers, thereby increasing
the speed of the manufacturing process. The objectives
of JIT is to change the manufacturing system gradually
rather than drastically:
1. To be more responsive to customers,
2. To have better communication among departments and
suppliers,
3. To be more flexible,
4. To achieve better quality,
5. To reduce product cost.

19. waste
Definition
 “anything other than minimum amount of
equipment, materials, parts and working time
absolutely essential to production.”
“anything other than the absolutely minimum
resource of material, machines and manpower
required to add value to the product”.

20. THE SEVEN WASTESTHE SEVEN WASTES
Waste of over productionWaste of over production
Waste of waitingWaste of waiting
Waste of transportationWaste of transportation
Waste of processing itselfWaste of processing itself
Waste of stocksWaste of stocks
Waste of motionWaste of motion
Waste of making defective productsWaste of making defective products

21. Waste in Operations….

22. Waste in Operations….

23. 01/05/19

24. Why JIT needed?
JIT though cuts down drastically the inventory
at different stages.
It is a means of solving problems that block the
building of an excellent manufacturing
organization.
JIT approach, when applied systematically, reduces
or eliminates waste from purchasing,
manufacturing, distribution and all other support
activities of a manufacturing enterprise.

25. It helps in elimination of non-value-added
activities thereby adding to their efficiency
and profitability or cost savings.

26. JIT Action Areas…
Develop peopleDevelop people – increase skills,– increase skills,
productivity, moraleproductivity, morale
Eliminate waste in all areasEliminate waste in all areas
Optimize mOptimize materials handling and productionaterials handling and production
flowflow
ControlControl ToolingTooling
Increase qualityIncrease quality
Improve continuously!Improve continuously!

27. Benefits of JIT
Reduction in manufacturing lead time.
 Defect free production.
 Lower inventory investment.
 Greater conformance to the delivery
commitments.
Lesser cost of production
 Faster response to market needs.

28. Advantages of JIT
Reduced inventories of raw materials
purchased parts, work in progress and finished
goods.
Lower per unit cost due to reduced cycle
time and lower inventories.
Early detection and correction of non-
conformances thereby improving quality of
purchased parts.
Zero or reduced incoming inspection.
Greater administration efficiency due to
lesser no suppliers, minimal order release
work and simplified receiving activities.

29. Disadvantages of JIT
 The organization is highly vulnerable to supply
failures.
 Buying in bulk may outweigh the savings due to
reduction in inventory.
 Suppliers may raise their prices to cover for
cost of delivery, small production runs,
increased paper work, inventory costs of
stocks to be used by them etc.

30. Techniques of JIT
 Set up time reduction
 Autonomous or modular cell
 JIT layout
 The Pull system (the KANBAN SYSTEMKANBAN SYSTEM of
production control)

31.  Buffer stock removal
 Continuous improvement
 Total productive maintenance
 Quality-at-source
 Jus-in-time purchasing

32. Set Up Time Reduction
Set up time is the time required to change from
one job to another

34. Autonomus Modules or Cells

40. KANBAN

46. Kanban System
The word KANBAN means a sign board of a store or shop,
but in our context It simply means any small sign
displayed in front of a worker.
KANBAN has two functions.
 To contain information that serves as a work order.
To move with actual material.

47. Kanban Rules
Do not send defective products to subsequent process.
The subsequent process comes to withdrawn only what is
needed. This is the
PULL SYSTEM OF DEMAND.
Produce only the exact quantity withdrawn by the
subsequent process.
Equalise production.
KANBAN is a means to fine tuning.
Stabilise and rationalise the process.

48. Kanban system

50. KANBAN CARD

52. Reducing overproduction &
Inventory

54. JIT AND QUALITY PRODUCTION
Cooperation of Company Vendors
Need of self Discipline.
Commitment of Top Management.
KANBAN Production information System

55. MANAGEMENT'S RESPONSIBILITY
Motivation
Training
Leadership