JUST IN TIME

 Just in time manufacturing is a philosophy rather

than a technique. By eliminating all wastes and
seeking continuous improvement, it aims at
creating a manufacturing system that is
responsive to the market needs.
 Just in time system operates with very low work
in process inventory and often with very low
finished goods inventory
According to Voss, JIT is viewed as a “Production
methodology which aims to improve overall
productivity through elimination of waste and
which leads to improved quality”.
SEVEN WASTES
 Shigeo Shingo, a Japanese JIT authority and engineer at the
Toyota Motor Company identifies seven wastes as being
the targets of continuous improvement in production
processes. By attending to these wastes, the improvement
is achieved.
1. Waste of overproduction: Eliminate by reducing set-up
times, synchronizing quantities and timing between
processes, layout problems, layout problems. Make only
what is needed now.
2. Waste of waiting: Eliminate bottle necks and balance
uneven loads and flexible workforce and equipment.
3. Waste of transportation: Establish layouts and locations
to minimize transportation and handling if not possible to
eliminate.
4. Waste of processing itself: Question regarding the
reasons for existence of the product and then why each
process is necessary.
SEVEN WASTES
5. Waste of stocks: Reduce all other waste stocks.
6. Waste of motion: Study motion for economy
and consistency. Economy improves
productivity and consistency improves quality.
First improve the motions, then mechanise or
automate. Otherwise, there is a danger of
automating the waste.
7. Waste of making defective products: Develop
the production process to prevent defects from
being produced, so as to eliminate inspection.
At each process, do not accept defects and
make no defects.
 BASIC ELEMENTS OF JIT
1. Flow layout: The physical layout of production facilities is
arranged, so that the process flow is streamlined, i.e. for
each component, the proportion of value-added time
should be more, there should be minimum queuing and
non-value-added times.
2. Use of dedicated lines, U-shaped or parallel lines, use of
small machines is preferred. Flexibility of equipment is
essential to adjust quickly to changing market demand.
3. Smooth build up rate: The buildup rate should be smooth
over a monthly cycle. To achieve this, under capacity
scheduling is resorted to so that they can respond to
demand changes.
4. Mixed model scheduling: JIT objective is to match the
production rate to demand as closely as possible. One way
of doing this is to increase the flexibility of production lines
to allow concurrent assembly of different models on the
same line.
5. Buffer stock (safety stock) removal: Constant elimination of
buffer stocks is required.
6. Kanban card : Kanban is the Japanese word for a Sign
Board. It is a system which enables a manufacturing facility
to estimate as to What to produce, how to produce and when
to produce. It is a responsive mechanism that helps schedule
the reorder point rather than maintaining a level of inventory.
It controls the rate of production as per the rate of demand.
So it response to the demand passed by the end customer.
7. Quality: The achievements of high quality product is a
prerequisite of successful JIT. Zero defect, statistical process
control and worker centred quality are commonly used
quality programmes.
8. Product and process simplification: This is achieved through
a) reducing product range
b) Simplification of methods of manufacture
c) Simplification through component item standardization.
9. Standard container: JIT emphasize small standardized
containers. This simplifies materials movement and use of
material handling equipment.
10. Preventive maintenance: JIT requires removal of causes of
uncertainty and waste. Breakdown is a major cause of the
uncertainty. Rigorous preventive maintenance attempts to
remove the uncertainty.
11. Flexible workforce: This is the critical requirement of JIT.
Flexible workforce is developed through cross functional
training. It is necessary to match production rate and
demand rate as closely as possible.
12. Organization in modules or cells: Many JIT factories are
organized in small autonomous modules or cells, each cell
being totally responsible for its own production and supply
of adjacent module. The cell are designed so that material
flow between the cells is minimized.
13. Continuous improvement: JIT is not one time
effort, it is a philosophy of continuous
improvement. It seeks the involvement of
everyone in the continuous improvement.
14. JIT purchasing: Materials and components are
purchased in accordance with well defined
requirements in terms of quality, quantity and
delivery.
BENEFITS OF JIT
The most significant benefit of JIT is to improve the
responsiveness of the form to the changes in the market
place thus providing an advantage in competition. The
benefits are:
1. Product Cost: is greatly reduced due to reduction of
manufacturing cycle time, reduction of waste and
inventories and elimination of non-value-added
operations.
2. Quality: is improved because of continuous quality
improvement program's.
3. Design: Due to fast response to engineering change,
alternative designs can be quickly brought on the shop
floor.
4. Productivity improvement
5. Higher production system flexibility.
6. Administrative ease and simplicity.