Just-In-Time Manufacturing

Matt Schmidt Penn State University OISM 470W

Just-In-Time Manufacturing?

What is JIT Manufacturing?

Where did it come from?

What are the main principles? Is it easy to Implement?

What phrase best describes JIT?

Just-In Time Manufacturing

JIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality. JIT- operational management approach to achieve world class manufacturing. JIT- production is based on demand

History of JIT Manufacturing

Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry. Toyota Motor Company- Birthplace of the JIT Philosophy Under Taiichi Ohno.
W. Edwards Deming 14 points for Management

JIT is now on the rise in American Industries.

Principles Of JIT Manufacturing

Total Quality Management

Production Management
Supplier Management Inventory Management

Human Resource Management

Principles Of JIT Manufacturing

Total Quality Management

Production Management
Supplier Management Inventory Management

Human Resource Management

Total Quality Management

Seek long-term commitment to quality

efforts with continuous improvement

Quality must be a higher priority than cost Minimizing waste

Total Quality Management

Eliminate Quality Inspectors Quality is everyones responsibility

Do it right the first time

Principles Of JIT Manufacturing

Total Quality Management

Production Management

Supplier Management Inventory Management Human Resource Management

Production Management

Pull System vs. Push System

Pull = Made to order Push = Made for inventory

Flexability of the system Design For Testability In the process

Poka-Yoke= Mistake-proofing Throughout entire process

Production Management
Reduced lot sizes= Shorter cycle times Eliminate disruptions in the process Standardized Parts/ Simplicity

Production Management

Communication Techniques
Completion of task-Kanban Problem- Andon or siren/light

Stopping the process if something goes

wrong =Jidoka

Preventive Maintenance

Production Management at Toyota

Toyota uses a Kanban pull system throughout the production process. Each task in the process seems to take identical length and work content, so everyone is working at the same pace to reduce bottlenecks.

Principles Of JIT Manufacturing

Total Quality Management

Production Management

Supplier Management

Inventory Management Human Resource Management

Supplier Management

Establish Long Term Relationships with few suppliers. Delivery of Parts = 100% Defect Free
Where they are needed When they are needed The exact quantity

Work Together

Supplier Management
Elimination inspection of parts Information Systems

Eliminating barriers to information

Communicate problems to suppliers in a

positive manner.

Supplier Relations at Toyota

Toyota communicates their damand for parts 20 days in advance to their suppliers, with the right to change the forecast up to the 10th day.

Principles Of JIT Manufacturing

Total Quality Management

Production Management
Supplier Management

Inventory Management

Human Resource Management

Inventory Management
Eliminate Safety Stock = Zero Inventory

Reduce WIP

JIT is not an inventory control system Reduction in inventory opens up space

Inventory hides problems in a process. Water Level = Inventory Rocks = Problems in the system Boat = Company Operations

Principles Of JIT Manufacturing

Total Quality Management

Production Management
Supplier Management Inventory Management

Human Resource Management

Human Resource Management

Company-wide Involvement

Motivation for continuous improvement Problem Solving High Employee Interaction

Build Pride In Workmanship

Human Resource Management

Self-Inspection of work

Diversified Employees
Absenteeism To eliminate boredom in process

Management Support and Empowerment of workforce

Implementation Problems
Worker resistance

Lack of top management support

Lack of communication Lack of formal training

Most Important Question

What phrase best describes the

Just-In-Time philosophy?

Continuous Improvement

Summary
JIT- A philosophy of continuous improvement that puts emphasis on prevention rather than correction, and demands a company wide focus on quality.

References

Cammaranano, J. Lessons to be Learned: JIT. Atlanta, Georgia: Engineering and Management Press, 1997. Dear, A. Working toward JIT: Management Technology. London: Derek Doyle and Associates, 1988. Fisher, D. The JIT Self Test: Success Through Assesment and Implementation. Chicago, IL: Irwin Inc., 1995. Hernandez, A. JIT Quality: A Practical Approach. Englewood Cliffs, NJ: Prentice-Hall, 1993. Hutchins, D. Just-In-Time: Inventory Control. Brookfield, VT: Gower Publishing, 1988. OGrady, P.J. Putting the JIT Philosophy Into Practice. New York, NY: Nichols Publishing, 1988. Reinfeld, N.V. Handbook of Production and Inventory Control. Englewood Cliffs, NJ: PrenticeHall, 1987. Schneiderjans, M.J. Advanced Topics In JIT Management: JIT Systems. Westport, CT: Greenwood Publishing Group, 1999. Taver, R.W. Manufacturing Solutions for Consistent Quality and Reliability: The 9 Step Problem Solving Process. New York, NY: AMACON, 1995. Wesner, J.W., Hiatt, J.M., and Trimble, D.C. Winning with Quality: Applying Quality Principles in Product Development. Reading, MASS: Addison-Wesley Publishing Co., 1995.