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6.10.2010
Just-In-Time (JIT)
Learning objectives: Understanding the theory behind just-intime. Understanding when just-in-time is a suitable production system to use. Understanding the advantages of using just-in-time.
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What is just-in-time?
Just-in-time is an easy concept to understand. If you think about someone's journey to work, they could leave the house just-in-time to cycle to the train station, just-in-time to catch their train, which would get them to their place of work just-in-time, allowing them to be at their desk just-in-time to start work. Think about your journey here today. Could this be applied? 09:39 3 06/27/13 There is no problem with this concept;
What is just-in-time?
In engineering, using the just-in-time theory would allow the components that are needed to produce a product to be delivered to the worker, just-in-time. The products can then be made available for the customers just-in-time. This process allows for all types of stock, including materials and finished products, to be eliminated. Implementing a just-in-time structure can mean a company is adopting a lean 06/27/13 09:39 4 production system.
History of JIT
Ford Motor Company
Concept of dock to factory floor Required effective Freight Management System
1980s conclusion
Japanese industry worked smart - JIT Western industry worked JUST IN CASE
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Quick response (QR)- speed & flexibility Efficient Consumer Response (ECR)- speed & flexibility JIT Continuous reduction of waste Keiretsu Relationships- Including suppliers in JIT/TQM efforts
Quality is a necessary element and outcome of JIT to achieve low cost, high quality, & reduced lead times.
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Waste from Overproduction Waste of waiting/idle time Transportation Waste Inventory Waste Processing Waste Waste of Motion Waste from Product Defects
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Small production batches are accomplished with the use of kanbans a Japanese word for card. Although for JIT use, Kanban has come to mean a 06/27/13 09:39 15 signal to order or release material in the
Kanban
Kanban is the Japanese word for card The card is an authorization for the next container of material to be produced A sequence of kanbans pulls material through the process Many different sorts of signals are used, but the system is still called a kanban
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Kanban
1. User removes a standard sized container 2. Signal is seen by the producing department as authorization to replenish
Signal marker on boxes Part numbers mark location
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Withdrawal Kanban
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Kanban
Kanban Work cell Ship Raw Material Supplier Kanban Kanban Purchased Parts Supplier Subassembly Final assembly Kanban Kanban Finished goods Customer order
Kanban
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More Kanban
When the producer and user are not in visual contact, a card can be used When the producer and user are in visual contact, a light or flag or empty spot on the floor may be adequate Since several components may be required, several different kanban techniques may be employed
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More Kanban
Usually each card controls a specific quantity or parts Multiple card systems may be used if there are several components or different lot sizes In an MRP system, the schedule can be thought of as a build authorization and the kanban a type of pull system that initiates actual production
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Demand during lead time = 2 days x 500 cakes = 1,000 Number of kanbans =
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Advantages of Kanban
Allow only limited amount of faulty or delayed material Problems are immediately evident Puts downward pressure on bad aspects of inventory Standardized containers reduce weight, disposal costs, wasted space, and labor
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Disadvantages of JIT
1.Production is very reliant on suppliers and if stock is not delivered on time, the whole production schedule can be delayed 2. There is no spare finished product available to meet unexpected orders, because all product is made to meet actual orders however, JIT is a very responsive method of production
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