Just In Time

JIT (Just In Time)

Think of a situation where we produce goods only at the time when they are needed and in the quantity that is needed
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No WIP & FG inventories Suppliers convinced no RM inventory zero or equal to zero inventory

Concept borrowed from American supermarkets Its not an inventory management system but rather a business philosophy JIT is about making the right quantity products in right time with zero defects (i.e right quality)
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Goals Of JIT
Produce goods that customers want Operate at customers rate Ensure perfect quality Zero unnecessary lead time Optimum utilisation of resources GOAL of JIT is to have ideal production system

Requirements for an effective JIT system

Yo-i-don (Ready-set-go) and Standardisation
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All have same pre-planned cycle time Andon (red light) after finishing Breaking huge production task to single unit targets 50% - 70% of set-up time can be reduced Single setup and one touch setups Shift from fix it when it breaks to zero break-downs Acceptable quality level (AQL)

Smoothing of production
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Short set-up times

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Improved Maintenance
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Improved Quality
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JIT encourages good quality products within set cycle time 4

Requirements for an effective JIT system . . contd

Multiskilling
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PDCA
Produce and supply materials when required Take responsibility for quality Attitude to produce zero defects Vision and good leadership

Vendor Management
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Self Discipline
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Commitment of Top Management

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JIT cannot be quickly put in place and forgotten. Implementation requires a total commitment to operate in a better way a way of doing things right 5 Inattention is unforgivable

Benefits of JIT
No Inventory or Lot size No Waiting time Improved Quality Lower cycle time / lead time High variety available Faster market response Less investment in manufacturing and material handling facilities JIT is capable of taking large and sudden variations in demand pattern
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Elements of JIT
JIT Production

Produce what is required

JIT Distribution

Third Party Logistics Multiple product loading

JIT Purchasing

Have quality certified, less number of suppliers

KANBAN
Kanban is an information system used to control the number of parts produced in every process Forms / Types of Kanban

Vendor Kanban Withdrawal Kanban Production order Kanban

How Kanban works

Outbound Stock Point Completed parts with cards enter Outbound Stock Point Outbound Stock Point

When production is removed, place production cards in hold box

Production card authorises start of work

Production card

Workstation

Standard container

Kanban card

Stock point
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JIDOKA

JIDOKA
The second pillar of TPS, referred to as automation with human face or autonomation It allows the control system to supervise manufacturing, stopping any process immediately once the problem or error is detected It is intelligent enough to assess what is going on & act accordingly, as an human being might

Inspite of being the second pillar of TPS, least thinking is done in this area

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Components of JIDOKA
Andon Poka yoke Autonomation Total Productive Maintenance (TPM)

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Andon
Andon doesnt means STOP the process, It means HELP With Andon if the problem is not fixed before it reaches fixed position stop, the line will STOP

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Benefits of Andon
Process Control First time quality Rapid response Instant Feedback Teamwork Productivity Improved communications Status at a glance

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Components of JIDOKA
Andon Poka yoke

Autonomation
Total Productive Maintenance (TPM)

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Poka Yoke
The practice of striving towards zero defects by using techniques, standards and devices to prevent errors Error proofing devices should be: Simple Easy to install In expensive Developed by user Considered at design stage

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Role of mistake proofing device

1. To STOP the process

A device or technique is used to detect an abnormal or defective operation and stop the process

2. To CONTROL the process

Devices or techniques are used to stray away from standard operating procedures or to keep defective goods from being passed on to the next stage

3. To WARN that an error is about to occur

Use of buzzers, lights etc. to signal that a defect or abnormal operation is occurring or about to occur
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Steps for implementing mistake proofing

1. Specify / check item characteristics

Shape, Dimensions & Weight

2. Operation step method

During process and between process Compare what operators are doing against the Standard Operating Procedures (SOP)

3. Statistical Method

Counting, Remainder & Critical Condition

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Components of JIDOKA
Andon Poka yoke

Autonomation
Total Productive Maintenance (TPM)

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Autonomation
Human intelligence transferred to automated machinery to detect problems (defect) and automatically stop themselves Purpose is to prevent or detect defects

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Components of JIDOKA
Andon Poka yoke

Autonomation
Total Productive Maintenance (TPM)

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Total Productive Maintenance (TPM)

GOALS Eliminate all machine breakdowns HOW Cleaning, tightening & lubricating Inspect initial symptoms

Achieve a 100% on demand utilisation rate

Main GOAL of TPM is the machine should work & work well when needed the most

Adhere to standard work

Operator alertness

Root cause analysis

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Role of operator in TPM

Main Role

Operate Inspect Maintain Clean Adjust Record Problems

Support Role Report Abnormalities Assist maintenance Troubleshoot Modify TPM if needed Participate in problem solving and special project teams

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