Professional Documents
Culture Documents
JIT and
Lean Operations
McGraw-Hill/Irwin
Learning Objectives
JIT/Lean Production
Just-in-time (JIT): A highly
coordinated processing system in which
goods move through the system, and
services are performed, just as they are
needed,
Goal of JIT
The ultimate goal of JIT is a balanced
system.
Achieves a smooth, rapid flow of
materials through the system
15-4
Eliminate disruptions
Product
Design
Process
Design
Eliminate waste
Personnel
Elements
Manufacturing Planning
Building
Blocks
15-5
Supporting Goals
Eliminate disruptions
Make system flexible
Eliminate waste, especially excess
inventory
15-6
Sources of Waste
Overproduction
Waiting time
Unnecessary transportation
Processing waste
Inefficient work methods
Product defects
15-7
Kaizen Philosophy
Waste is the enemy
Improvement should be done gradually and
continuously
Everyone should be involved
Built on a cheap strategy
Can be applied anywhere
15-8
15-9
Vendor relations
Human relations
Technology management
Materials and inventory management
15-10
15-11
Product Design
Standard parts
Modular design
Highly capable production systems
Concurrent
engineering
15-12
Process Design
Small lot sizes
Setup time reduction
Manufacturing cells
Limited work in process
Quality improvement
Production flexibility
Balanced system
Little inventory storage
15-13
15-14
Single-Minute Exchange
Single-minute exchange of die (SMED): A
system for reducing changeover time
Categorize changeover activities
Internal activities that can only be done while
machine is stopped
External activities that do not require stopping
the machine
15-15
Production Flexibility
Reduce downtime by reducing
changeover time
Use preventive maintenance to
reduce breakdowns
Cross-train workers to help clear
bottlenecks
15-16
15-17
Quality Improvement
Autonomation
Automatic detection of defects during
production
Jidoka
Japanese term for autonomation
15-18
Production Flexibility
Balance system: Distributing the workload
evenly among work stations
Work assigned to each work station must be
less than or equal to the cycle time
Cycle time is set equal to the takt time
Takt time is the cycle time needed to match
customer demand for final product
15-19
Personnel/Organizational
Elements
Workers as assets
Cross-trained
workers
Continuous
improvement
Cost accounting
Leadership/project
management
15-20
Pull/Push Systems
Pull system: System for moving work
where a workstation pulls output from
the preceding station as needed. (e.g.
Kanban)
Push system: System for moving work
where output is pushed to the next
station as it is completed
15-22
Kanban Formula
N
DT(1+X)
C
Buyer
Buyer
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
15-26
Buyer
Buyer
First Tier Supplier
Second Tier Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
Supplier
15-27
15-28
Housekeeping Five Ss
1.
2.
3.
4.
5.
Sort
Straighten
Sweep
Standardize
Self-discipline
15-29
Table 15.3
Factor
Traditional
JIT
Inventory
Deliveries
Few, large
Many, small
Lot sizes
Large
Small
Setup; runs
Vendors
Long-term relationships
are unusual
Partners
Workers
15-30
Obstacles to Conversion
Management may not be committed
Workers/management may not be
cooperative
Difficult to change company culture
Suppliers may
resist
Why?
15-32
15-33
JIT in Services
The basic goal of the demand flow technology in
the service organization is to provide optimum
response to the customer with the highest
quality service and lowest possible cost.
Eliminate disruptions
Make system flexible
Reduce setup and lead times
Eliminate waste
Minimize WIP
Simplify the process
15-34
JIT II
JIT II: a supplier representative works
right in the companys plant, making
sure there is an appropriate supply on
hand.
15-35
15-36
15-37
Table 15.4
Elements of JIT
15-38
Table 15.4
Cross-trained employees
A pull system
15-39
15-40
15-41
15-42
15-43