Just-In-Time

1
Just-In-Time

• Eliminate Waste

2
Flexible Resources

• Multifunctional workers
• Operate more than one machine
• General-purpose machines
• Machines that were not highly specialized

3
Cellular Layouts

• Manufacturing cells
• Often U-shaped
• Work flows through cell in one direction and
  experiences little waiting

4
Pull System

• Coordinating production and delivery of materials
  and parts
• Traditionally, inventory has been used as a
  cushion against lapses in coordination and
  inventory can be huge
• Pull system observed at US supermarkets
• Safeway example

5
Pull System

• Do not order more product than can be used
• (or items that can be sold)
• Reversal of normal push system

6
Uniform Production Levels

• Smoothing production requirements on the final
  assembly line
• Better forecast
• Mixed production throughout the day in small
  quantities

7
Quality at the Source

• For JIT to work, quality has to be high
• No extra inventory to buffer against defective
  units
• Producing poor-quality items and reworking items
  or rejecting them is wasteful
• Workers are responsible for inspection
• NEVER pass along defective item

8
Quality at the Source

• Jidoka
• Authority to stop production line if quality
  problems were encountered
• Andons
• Call lights activated by switches
• Undercapacity scheduling
• Making time to plan, train, solve problems,
  maintain work environment

9
Quality at the Source

• Poka-yoke
• Foolproof device or mechanism that prevents
  defects from occurring
• Kaizen
• Continuous improvement

10
Benefits of JIT

• Reduced inventory
• Improved quality
• Lower costs
• Reduced space requirements
• Shorter lead time
• Increased productivity

11
Benefits of JIT

• Greater flexibility
• Better relations with suppliers
• Simplified scheduling and control activities
• Increased capacity
• Better use of human resources
• More product variety