You can get better details about JIT from this presentation.

1. TIME - TWO HOURS
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2. ABOUT HIRANO SAN
Full name - Mr HIROYUKI HIRANO
Author of - JUST IN TIME - FACTORY REVOLUTION
Consultant on - JIT
PREACHES & PRACTICES INNOVATION
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3. JIT FACTORY REVOLTUION
BY
Mr HIROYUKI HIRANO
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4. JIT FACTORY REVOLUTION
STEPS IN IMPLEMENTING JIT PRODUCTION
JUST IN TIME
STEP 5
MANPOWER REDUCTION
JIDOKA-HUMAN AUTOMATION MAINTENANCE & SAFETY
STANDARDISED OPERATIONS
VISUAL CONTROL
STEP 4
CHANGEOVER QUALITY ASSURANCE
LEVELLING
STEP 3
MULTI -PROCESS OPERATIONS KANBAN
FLOW MANUFACTURING
STEP 2
5S
STEP 1
AWARENESS REVOLUTION
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5. JIT FACTORY REVOLUTION
TOPICS
1 INTRODUCTION
2 AWARENESS REVOLUTION
3 5S
4 FLOW MANUFACTURING
5 STANDARD OPERATIONS
6 MULTI PROCESS HANDLING
7 REDUCING WORKER HOURS
8 LEVELLING PRODUCTION
9 JIDOKA
10 CHANGEOVER
11 QUALITY ASSURANCE
12 KANBAN
13 MAINTENANCE & SAFETY
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6. JIT FACTORY REVOLUTION
1 INTRODUCTION
CELL SHOULD BE FLEXIBLE
FLEXIBILITY TO ADAPT TO CHANGES IN DEMAND, PRODUCT MIX & PRODUCT DESIGN
WITHIN CELL - ONE PIECE FLOW
- REDUCED SETUP TIME
- IMPROVED M/Cs TO INFORM OPERATORS ABOUT PROBLEMS
- MEASURES TO PREVENT DEFECTS & BREAKDOWNS
BETWEEN CELLS - SMALL LOTS - UNIFORM SIZE - KANBAN
- PULL CONTROL
“JIT MEANS TRIMMING LOSSES - AN ORDEAL FOR SURVIVAL”
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7. JIT FACTORY REVOLUTION
2 AWARENESS REVOLUTION
ASSUME CURRENT PRODUCTION SYSTEM IS THE WORST
CHANGE IN THE WAY OF THINKING
INSTALL NEW CORPORATE CULTURE
OPERATORS TO LEARN NEW METHODS - TRAINING
HAVE CLEAR POLICIES FOR RESISITANCE
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8. JIT FACTORY REVOLUTION
TEN COMMANDMENTS OF INNOVATION
1 - DISCARD FIXED IDEAS
2 - THINK HOW IT CAN BE DONE THAN, HOW IT WON’T
3 - DENY STATUS QUO
4 - DON’T SEEK PERFECTION
5 - CORRECT MISTAKES AS SOON AS THEY ARE FOUND
6 - INNOVATION NEEDS NO MONEY
7 - PROBLEMS ARE OPPORTUNITIES TO USE OUR BRAINS
8 - ASK WHY 5 TIMES
9 - IDEAS OF 10 ARE BETTER THAN KNOWLEDGE OF 1
10 - INNOVATION NEVER ENDS
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9. JIT FACTORY REVOLUTION
INNOVATION CYCLE
ACT PLAN
IMPROVEMENT CYCLE
KAIZEN
CHECK DO
AC T
T
RGE
TA
INNOVATION CYCLE VISION /
CHECK IMAGE PICTURE /
KAIKAKU DREAM
PL
DO AN
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10. JIT FACTORY REVOLUTION
3 5S
SEIRI - PROPER ARRANGEMENT
SEITON - ORDERLINESS
SEISO - CLEANLINESS
SEIKITSU - CLEANUP
SHITSUKE - DISCIPLINE
WE ARE BEHIND TIMES IF WE STILL SWEEP THE FLOORS
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11. JIT FACTORY REVOLUTION
4 FLOW MANUFACTURING
PRODUCING ONE PIECE AT A TIME
CYCLE TIME IS THE TIME IT TAKES TO CARRY ONE PART ALL THE WAY THROUGH THE CELL
WORKING HOURS / DAY
TAKT TIME =
DAILY RATE
MONTHLY QUANTITY REQUIRED
DAILY RATE =
WORKING DAYS PER MONTH
MULTI PROCESS HANDLING & SMALL INLINE MACHINES
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12. JIT FACTORY REVOLUTION
5 STANDARD OPERATIONS
RULES & METHODS TO PRODUCE QUALITY PRODUCTS,
SAFELY & INEXPENSIVELY
BY EFFICIENT ARRANGEMENT OF PEOPLE, PRODUCT & MACHINES
STANDARD OPERATIONS BULLETINS & MANUALS ON WORK METHODS
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13. JIT FACTORY REVOLUTION
6 MULTI PROCESS HANDLING
ONE OPERATOR HANDLES SEVERAL PROCESS IN A CELL
DE-LINEATE JOBS PERFORMED BY MACHINE & OPERATORS
(MACHINES CAN WORK INDEPENDENTLY)
MAKE CELLS U SHAPED & GIVE MACHINES JIDOKA FUNCTION
OPERATORS TO STAND WHILE WORKING
TRAIN OPERATORS TO BE MULTI SKILLED
FOLLOW RABBIT CHASE - PRODUCTIVITY MAY GO UP
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14. JIT FACTORY REVOLUTION
7 REDUCING OPERATOR HOURS
TO PRODUCE GOODS WITH MINIMUM NUMBER OF OPERATORS
ADJUSTING TO CHANGING MARKET REQUIREMENTS
MAKE MACHINES EASY TO MOVE BY ATTACHING CASTORS
STANDARDISE OPERATIONS SO EVERYONE CAN PERFORM THE JOB
TRAIN OPERATORS THROUGH JOB ROTATION TO BE MULTI SKILLED
DO NOT ASSIGN FIXED NUMBER OF OPERATORS TO ANY PROCESS
IT SHOULD VARY ACCORDING TO PRODUCTION QUANTITY
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15. JIT FACTORY REVOLUTION
8 LEVELLING PRODUCTION
TO PRODUCE THE SAME QUANTITY OF AN ITEM EVERY DAY
CALCULATE CYCLE TIMES BASED ON MONTHLY VOLUMES
MAKE CYCLE LIST BASED ON CYCLE TIME
SHORTEN CHANGEOVER TIMES
CREATE SMOOTH FLOW
INFORMATION & PARTS ARE DELIVERED TO THE LINE SEVERAL TIMES DAILY
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16. JIT FACTORY REVOLUTION
LINE CYCLE TIME = 4.8 min / UNIT
WORK TIME = 480 min / DAY
MONTHLY REQUIRED - X = 1000
Y = 600
Z = 400
2000
MONTHLY PRODUCTION SCHEDULE X = 50 / DAY
(20 WORKING DAYS) Y = 30 / DAY
Z = 20 / DAY
DAILY PRODUCTION SCHEDULE X = 50 - 08:00 - 12:00
Y = 30 - 12:30 - 15:00
Z = 20 - 15:00 - 16:30
LEVELLED PRODUCTION X = 50 - ONE IN 9.6 min
Y = 30 - ONE IN 16 min
Z = 20 - ONE IN 24 min
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17. JIT FACTORY REVOLUTION
SEQUENCING OF PARTS FOR LEVELLED PRODUCTION
X - ONE IN 9.6 MINUTES Y - ONE IN 16 MINUTES Z - ONE IN 24 MINUTES
Z X Y X Y X Z X Y X Y X Z X Y X Y X Z X Y X Y X Z
4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8
4.8 9.6 14.4 19.2 24.0 28.8 33.6 38.4 43.2 48.0 52.8 57.6 62.4 67.2 72.0 76.8 81.6 86.4 91.2 96.0 100.8 105.6 110.4 115.2 120.0
At the end of 480 minutes X 50
Y 33
Z 17
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18. JIT FACTORY REVOLUTION
9 JIDOKA
AUTOMATION WITH A HUMAN TOUCH
AUTONOMATION - AUTOMATIC CONTROL OF DEFECTS
INSTALL A MECHANISM ( SENSOR) IN THE MACHINE
THAT PERMITS THEM TO DETECT DEFECTS
&
STOPS THE MACHINE WHEN DEFECTS OCCUR
POKA YOKE
MANUAL ----- MECHANISATION ---- AUTOMATION ---- AUTONOMATION
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19. JIT FACTORY REVOLUTION
10 CHANGEOVER
THE TIME BETWEEN THE LAST GOOD PRODUCT OF ONE TYPE TO THE FIRST GOOD
PRODUCT OF THE NEXT TYPE
CHANGEOVER TIME IS THE SUM OF INTERNAL & EXTERNAL TIMES
INTERNAL - PROCESS MUST BE STOPPED TO PERFORM CHANGEOVER
EXTERNAL - TIME SPENT WHILE THE PROCESS IS RUNNING
STEP 1 - ANALYSE CHANGEOVER
STEP 2 - IDENTIFY & ELIMINATE WASTE
STEP 3 - MAKE INTERNAL CHANGEOVERS EXTERNAL
STEP 4 - IMPROVE INTERNAL CHANGEOVERS
(Bolts tighten with one turn, eliminate adjustment…)
STEP 5 - IMPROVE EXTERNAL CHANGEOVERS
(Use charts, assign workers…..)
BOLTS ARE OUR ENEMIES
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20. JIT FACTORY REVOLUTION
11 QUALITY ASSURANCE
MAINTAINING QUALITY USING OPERATORS, MANUFACTURING SYSTEM DESIGN &
PRODUCTION METHODS TO SATISFY CUSTOMER NEEDS
STEP 1 - OPERATOR - Disciplined, well trained & multi skilled
STEP 2 - MATERIALS - Source control
STEP 3 - MACHINES - Pokayoke, TEI for safety & maintenance
STEP 4 - METHOD - Flow manufacturing cells & standard operations
STEP 5 - INFORMATION - Visual control
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21. JIT FACTORY REVOLUTION
12 KANBAN
A TOOL THAT CARRIES INFORMATION TO FACILITATE PRODUCTION CONTROL
RULES
- SUBSEQUENT PROCESS GOES TO FORMER PROCESS FOR PARTS
- FORMER PROCESS PRODUCES QUANTITY REMOVED BY SUBSEQUENT PROCESS
- QUALITY IS BUILT INTO THE PRODUCT - DEFECT NOT SENT TO NEXT PROCESS
- KANBAN ALWAYS ACCOMPANY PRODUCT - VISUAL CONTROL
- PRODUCTION QUANTITIES ARE LEVELLED TO AVOID FLUCTUATIONS
- REDUCING KANBAN REVEALS PLACES WHERE IMPROVEMENTS ARE NEEDED
PRODUCTION ORDERING KANBAN - WITHDRAWAL / CONVEYANCE KANBAN
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22. JIT FACTORY REVOLUTION
13 MAINTENANCE & SAFETY
3 RULES OF MAINTENANCE
CLEAN UP
OIL APPLICATION
CHECK
4 RULES OF SAFETY
SEPARATE MACHINES FROM OPERATORS
FOLLOW SAFETY STANDARDS
FOLLOW RULES
FIND REAL CAUSES & PREVENT
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23. HIRANO SAN
GUIDELINES
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24. HIRANOSAN GUIDELINES
DREAM
CURRENT
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25. HIRANOSAN GUIDELINES
Use KAIKAKU in place of KAIZEN
KAIZEN KAIKAKU
(Continuos improvement) (Innovation)
Small change Big change
making better Revolution
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26. HIRANOSAN GUIDELINES
Use JIT improvement in place of IE improvement
IE improvement JIT improvement
(inductive approach) (deductive approach)
ANALYSIS OF CURRENT CONDITIONS IDEAL SYSTEM AS GOOD
INNOVATION = IN NOVA TION
INTO THE NEW STAR = FUTURE
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27. HIRANOSAN GUIDELINES
STEPS FOR KAIKAKU
FOREST
(MORI)
STEP : 1
STEP : 2 SMALL FOREST
(HASHI)
SINGLE TREE
STEP : 3 (KI)
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28. HIRANOSAN GUIDELINES
STEPS FOR KAIKAKU
SUPPLIER
D C B A
E
STEP : 1 AS A WHOLE
F
G H I J
CUSTOMER8
D C B A
E
STEP : 2 IN A CELL
F
G H I J
IN A MACHINE
STEP : 3
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29. HIRANOSAN GUIDELINES
Guidelines
* Focus on managament benefit (Watch the forest)
IE benefit will not be much visible & require
money (Ki)
* Introduce “Rabbit chase” (including sub assembly)
* Have only one hour stock for process
* Introduce Auto door open & close
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30. HIRANOSAN GUIDELINES
Guidelines
* Introduce auto ejection of component
* Introduce auto fixture cleaning
* Have uniform cycle time
* Have single Input / Output point in a machine
* Do not have common machine for two parts in a cell
* Standardize process sign board
* Adhere to 3R (3-regulations)
1. Name 2. Quantity 3. Location
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31. HIRANOSAN GUIDELINES
Guidelines
* Introduce single piece work flow
1. Fix the WIP required
2. No Dango production
* Big sign board
(nick name should be decided by concerned operators)
* Have KAIKAKU board in cell
* Empty bin should be kept on bottom rack
(without reversing)
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32. HIRANOSAN GUIDELINES
Guidelines
* Have separate trolley for “tested ok”&“to be tested”
(Tsurube concept)
* We must figurise operator movement - operator to be on the move
(operator should stand only while working)
* Use both hands wherever required
* KIT implementation in engine assy
(for big parts which require body twist while picking & occupying more space)
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33. HIRANOSAN GUIDELINES
Guidelines
* Work flow line should be “straight line”
(3M I - Man, Machine, Material & Information)
No shoulder movement
(paper kept under the arm should not fall)
Loading point should be at elbow level
No up&down (DEKO BOKA)or zig-zag
* No back tracking
* No return movement without any work
(Loading & unloading should be done by the same person)
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34. HIRANOSAN GUIDELINES
Guidelines
* Implement the KAIKAKU points immediately
within one day - A rank
within two days - B rank
more than two days - C rank
if it is required to have time more than three days,
then plan today and have A rank for plan
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35. HIRANOSAN GUIDELINES
MUDA TORI
(PROCEDURE TO REMOVE WASTE)
FOR PRODUCTIVITY TO IMPROVE : NEVER SMALL ISLANDS - ONLY BIG ISLAND
A B C
SMALL ISLANDS
BIG ISLAND
ABC
STEP I - HITO ATSUME
OPERATOR GATHER
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36. HIRANOSAN GUIDELINES
MUDA TORI - contd...
(PROCEDURE TO REMOVE WASTE)
AB BC
STEP II - SHIGOTO ATSUME
VALUE GATHER
STEP III - MUDA ATSUME
WASTE GATHER
STEP IV - SHOUZIN
RESULT
TOOLCHANGE IN A BIG ISLAND - STOP ALL MACHINES AND DO
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37. HIRANOSAN GUIDELINES
TSURUBE
(Pronounced as THU RU BE, means SUPPLY ONE, RECEIVE ONE)
400 Years ago
in Japan
IF, IN A CELL, A PART HAS TO GO
OUT FOR AN INTERMEDIATE
OPERATION, FOLLOW TSURUBE
SYSTEM
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38. HIRANOSAN GUIDELINES
REVERSE FLOW OPERATION OF A CELL
OUT IN
SEIJUN - CORRECT SEQUENCING 7 6 5 4 3 2 1
MAN
MAN & WORK FLOW IN THE SAME
DIRECTION WORK
1 2 3 4 5 6 7
IN OUT
IN OUT
1 2 3 4 5 6 7
MAN
GYAKUJUN - REVERSE SEQUENCING
WORK
MAN & WORK FLOW IN OPPOSITE
DIRECTIONS 1 2 3 4 5 6 7
JAPANESE - IN RANK A LINES OUT
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39. HIRANOSAN GUIDELINES
DETAILS AT ENTRANCE OF A CELL
CELL NAME BOARD
WHEEL HUB CELL
R-50
F-40 R-40
T
R W AS H B RO R&F-3
0
ACH DRILL
0-F
2
CELL LAYOUT T
R RT
NU
0
F-1
R-10 R-20 RN
P TURN TURN
P TU
TAKT TIME = 104 SECONDS
TAKT TIME / CYCLE TIME
CYCLE TIME = 129 SECONDS
SHOP SIGN BOARD FOR ALL AREAS - VCS ON TOP OF BOARDS
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40. HIRANOSAN GUIDELINES
DETAILS AT ENTRANCE OF A CELL - contd...
MAN MACHINE CHART
HAND -
MACHINE -
WALKING -
WAITING -
PROCESS No. - 10
PROCESS DETAILS PROCESS NAME - TURNING & FACING
CYCLE TIME - 108 SECONDS
OPERATORS NAME &
PHOTO
M1033 - LOKESHA M1007 - NAGARAJA
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41. HIRANOSAN GUIDELINES
CELL DESIGN
OPERATOR / PART
FLOW DIRECTION TO
BE ANTICLOCKWISE
BROAC
R-40
TR
DRILL
R&F-30
R-50
W ASH
F-40
LOCATION FOR
H
0-F
2
TROLLIES & PALLETS
RT
NU
TR
TO BE CONVENIENT
TO OPERATOR 0
F-1
R-10 R-20 RN
P P TU
TURN TURN
OPERATOR WALKING
ZONE INSIDE CELL TO BE
MARKED BY WHITE LINE -
FOR FREE MOVEMENT
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42. HIRANOSAN GUIDELINES
CELL DESIGN
OPERATOR HAND MOVEMENT TO BE AS A FLOW
NO BACK TRACKING / NO SHOULDER MOVEMENT
OPERATOR EYE LEVEL TO BE MAINTAINED AT SAME LEVEL WITHIN THE CELL
PROVIDE REMIDER TOKENS FOR OPERATORS TO USE DURING BREAKS
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43. HIRANOSAN GUIDELINES
CELL DESIGN - contd...
FLOW DIRECTION TO
BE MARKED ON
CHUTES
DENOTE PROCESS TIMES IN SECONDS & SETUP TIMES IN MINUTES
GAUGES TO BE KEPT ON THE MACHINE - NOT ON GAUGE STANDS
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44. HIRANOSAN GUIDELINES
CELL DESIGN - contd...
MACHINES TO BE CLOSE TO EACH OTHER
- BRING CHECK POINTS TO REAR OR FRONT OF MACHINE
- MAKE ACCESSORIES BEHIND THE MACHINE EASILY MOVABLE
- AS A LAST OPTION MOVE MACHINES APART
DO NOT HAVE SNAKES ON THE FLOOR
LOOSE WIRES
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45. HIRANOSAN GUIDELINES
CELL DESIGN - contd...
PROVIDE TAB SWITCH FOR CYCLE START
PROVIDE AUTO UNCLAMP & AUTO UNLOADING
IT IS CHEAPER TO AUTOMATE UNLOADING THAN LOADING
eg: NET TO CATCH PART WHEN CHUCK IS OPENED / EJECTOR IN
THE FIXTURE WITH CHUTE TO BRING PART OUT
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46. HIRANOSAN GUIDELINES
CELL DESIGN - contd...
AT EACH MACHINE OPERATOR TO LOAD PART, PICK UNLOADED PART & HIT TAB SWITCH
AS HE MOVES TO NEXT MACHINE
OPERATOR TO OPERATE ALL MACHINES - MPO - RABBIT CHASE
OPERATOR NOT TO WATCH THE MACHINE - MAN MACHINE SEPARATE
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47. HIRANOSAN GUIDELINES
CELL DESIGN - contd...
PROVIDE WIRE IN FRONT OF MACHINES TO HANG VCS
PROVIDE PROPER ILLUMINATION TO INSIDE OF CELL
HAVE ALL DETAILS DISPLAYED RATHER THAN IN FILES - OPEN SYSTEM
MONITOR PRODUCTIVITY OF CELL - OUTPUT / MAN
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48. HIRANOSAN GUIDELINES
TYPES OF CELLS
U LINE
W LINE
T LINE
PLUS LINE
FLOWER LINE
HAVE SIGNAL AT CENTER TO INDICATE TO OPERATOR WHICH CELL TO OPERATE
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49. HIRANOSAN GUIDELINES
ASSEMBLY
OPERATION TIME
BALANCING RATIO = x 100
TAKT TIME x TOTAL No. OF STAGES
LOSS RATIO = 100 - BALANCING RATIO
MARK LINE ON CONVEYOR TO INDICATE START OF WORK FOR OPERATOR
TIME BETWEEN STOP OF WORK & COINCIDING OF LINE IS SLACK IN THAT STAGE
WAITING MUDA WILL BE VISIBLE
MARK IN & OUT ON SUPERMARKET STANDS TO INDICATE FLOW OF PARTS
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50. HIRANOSAN GUIDELINES
ANDONS
AAASDASDKRWQEOF
EMPTY FULL
KJFSDKLJKFASD4
TAXI ANDON
SEPARATION
HIRE ANDON ROW A ROW B
CONCENTRATION 1 2 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18
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51. HIRANOSAN GUIDELINES
ANDONS
ALL ANDONS TO BE OF TSL TSL
TC20 TC30 TC20 TC30
THE SAME ORDER
ALL ANDONS TO BE OF
THE SAME HEIGHT -
VISIBLE FROM
GANGWAY TSL TSL
TC20 TC30 TC20 TC30
PET BOTTLES - LOW COST
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52. HIRANOSAN GUIDELINES
THREE REGULATION FOR KEEPING PARTS
Bolts
1 - PROVIDE LOCATION
2 - PROVIDE IDENTIFICATION / NAME BOARD
Bolts
4
Pallets
1000x4
3 - SPECIFY QUANTITY
SPECIFY INVENTORY OF MATERIAL IN DAYS - INVENTORY OF WIP IN HOURS
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53. HIRANOSAN GUIDELINES
STORAGE OF PARTS
DO NOT KEEP PARTS ABOVE EYE LEVEL
DO NOT KEEP PARTS BELOW KNEE LEVEL
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54. HIRANOSAN GUIDELINES
YELLOW LINE
YELLOW LINE IS A WALL
CANNOT / DO NOT CROSS IT
MARK TIGER LINE FOR CROSSING
YELLOW LINE - MEN & MATERIAL
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55. HIRANOSAN GUIDELINES
YELLOW LINE
PROVIDE CHAMFERS AT
CORNERS OF GANGWAYS
MARK ARROWS ON GANGWAYS TO
SHOW WALKING DIRECTION O
P
S
T
STOP
MARK “STOP” SIGN AT
INTERSECTIONS OF GANGWAYS
AVOID PROTRUSIONS INTO THE GANGWAY - YELLOW LINE IS A WALL
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56. HIRANOSAN GUIDELINES
KAIKAKU MEASURES
* Productivity - In terms of out/shift
* Inventory - Total WIP
* Lead time - Time to convert raw material to finish
* Walking distance - In terms of steps/cycle
* Operators - In numbers
* Cycle time - Rhythm at which product comes out
* Takt time - Available time in sec / (qty. to be supplied)
(does not include allowance)
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57. HIRANOSAN GUIDELINES
Implement “Self KAIKAKU”
* Understand JITs 10 commandments
* Understand Hiranosan’s guidelines
* Conduct audit assuming yourself as Hiranosan
* Follow the KAIKAKU steps
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58. BIG ISLAND - WHEEL HUB & PANEL
OUTPUT (Scooty & Spectra) - 600 / day in 2 shifts
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59. TVS-Mysore