The JIT concept of production was introduced in Japan under the name of Kanban.
According to this concept material and components are supplied to the work station just
at the time they are required for use. It otherwise means, whatever materials and
components are needed for a shift are received at the beginning of the shift and converted
into finished goods, leaving nothing to be carried at the end of the shift.. Therefore JIT
emphasizes waste reduction, total quality control and devotion to the customer.
JIT is a logistic approach, wherein the level of inventory is kept at the bare minimum
because they are made to arrive just in time when they are needed to be used. It means
that the various vendors are working in unison with the manufacturing organization as a
single team, dedicated to act in unison, wherein the production and supply schedules are
matched perfectly and operate in absolute synchronized manner.
In the above discussion it can be seen that JIT means handling the inventory in a very
disciplined way. It requires changes in culture. JIT also encompasses the Japanese
managerial characteristics i.e. lifetime employment, implicit control mechanisms,
collective decision making, collective responsibility and holistic concern for employees.
JIT applies to all functions of a company not just the operations.
They are seven kind of wastes according to Shigeo Shingo a recognized JIT authority
and a Engineer at Toyota Motor Company. The table below lists the seven wastes as the
target for continuous improvement in production process.
1. Waste of overproduction.
Eliminate by reducing setup times, synchronizing quantities and timing between
processes, compacting layout, visibility, and so forth. Make only what is needed now.
2. Waste of waiting.
Eliminate through synchronizing work flow as much as possible, and balance uneven
loads by flexible workers and equipment.
3. Waste of transportation.
Establish layouts to make transport and handling unnecessary if possible. Then
rationalize transport and material handling that cannot be eliminated.
5. Waste of stocks.
Reduce by shortening setup times and reducing lead times, by synchronizing work
flows and improving work skills, and even by smoothing fluctuations in demand for
the product. Reducing all the other wastes reduces the waste of stocks.
6. Waste of motion,
Study motion for economy and consistency, Economy improves productivity, and
consistency improves quality. First improve the motions, then mechanize or
automate. Otherwise there is danger of automating waste.
By applying this philosophy many companies are improving their productivity. However
incorporating JIT requires a heavy commitment of time and rigorous discipline upon the
organization. Shingo sys that it took 29 years to implement the JIT system and it will take
most other companies another ten years to obtain similar results
The following sections will cover some of the aspects of JIT and Japanese manufacturing
systems like
• Total Quality Control
• House keeping
• Visual Control
• Andon / Jidoka / Poka Yoka
• Pull coordination and kanban
• Set up time reduction
• Flexibility
• Preventive maintenance
• Purchasing.
•
After a rather fascinating discussion on wastes, it’s time we considered:-
Similarly, Richard Schonberger identifies nine simple lessons from the Japanese. These
lessons focus on
1. Management technology
2. JIT production
3. TQC
4. Behavioral techniques
5. Plant configurations
6. Flexibility
7. Purchasing
8. Self improvement of work quality
9. Striving for simplicity in all things.
The term Total Quality Control (TQC) originated with the book by the name, written by
Armand V. Feigenbaum. As applied by the Japanese TQC is a detailed approach to
quality and it relates to every facet of the business.
Total quality control is an effective system for integrating the quality development,
quality-maintenance, and quality-improvement efforts of the various groups in an
organization so as to enable marketing, engineering, production, and service at the most
economical levels which allow for full customer satisfaction.
The content and its essentiality to the achievement of business results make total quality
control a new and important area of management. As a focus of managerial and technical
leadership, total quality control has produced outstanding improvements in product
quality and reliability for many organizations throughout the world Moreover, total
quality control has achieved progressive and substantial reductions in quality costs.
Through total quality control, company managements have been able to deal from
strength and confidence in the quality of their products and services, permitting them to
move forward in market volume and product mix expansion with a high degree of
customer acceptance and profit stability and growth.
Total quality control provides the fundamental basis of positive quality motivation for all
company employees and representatives, from top management through assembly
workers, office personnel, dealers, and service people. And a powerful total-quality-
control capability is one of the principal company strengths for achieving vastly
improved total productivity.
Effective human relations is basic to quality control A major feature of this activity is its
positive effect in building up employee responsibility for, and interest in, product quality.
In the final analysis it is a pair of human hands, which performs the important operations
affecting product quality. It is of utmost importance to successful quality-control work
that these hands be guided in a skilled, conscientious, and quality-minded fashion.
Sound technological methods of Total Quality Control are also basic. A variety of these
methods is now being used. Included are activities for specifying engineering tolerances
in user-oriented terms, accelerated test methods for evaluating component and systems
reliability, classifying quality characteristics, vendor rating methods, sampling-inspection
techniques, process-control techniques, design of quality-control measuring equipment,
computer-based quality data processing, gagging systems, standards establishment,
product-quality evaluation and rating schemes, application of statistical techniques from
X and R charts to designed experiments, and many others.
It is interesting to note that these individual methods have themselves been used as
definitions for quality control over the years. The written and spoken word often finds
quality control defined as some form of sampling inspection, as a portion of industrial
statistics, as reliability work, or as simply inspection or testing. These several definitions
have described only individual parts of, or methods in, an overall quality-control
program. They may have contributed to the confusion with which the term is sometimes
associated in industry.
The terms "quality control" and "quality assurance" have come to have different
meanings in some organizations-each term referring to different aspects of customer
quality –satisfaction activity. TQC programs in their operations include and integrate the
actions involved in the work covered by both the terms.
The Japanese manufacturing houses adopted TQC fully and realized the benefits for
example a company in a five year period improved defect rates by a factor of 25 from
suppliers and a factor of 33 times internally. Other JIT statistics improved as well.
To illustrate another success, consider these comparative levels of quality:-
US companies measure quality levels in terms of percentages i.e. parts defective per
hundred as compared to Japanese who measure in levels of parts defective per million
Japanese competitiveness owes and directly relates to American Quality Guru Dr. W.
Edwards Deming who has been closely associated with Japanese quality programs since
1950 when he was invited to address the Union of Scientists and Engineers about
improving the quality of products in industry. He estimated that 85% of the quality
problems are due to management and production systems.
3. Cease dependence on mass inspection Deming says that routine large scale inspection
to improve quality is equivalent to 'planning for defects'. Why pay workers to make
defects and then to correct them? Quality comes not from inspection but from
improvement of the process.
4. End the practice of awarding business on the has is of price tag only The buyer
company must change its policy from lowest initial cost of material purchased to lowest
total cost. Buyers should seek the best quality in a long-term relationship with a single
vendor for anyone item.
5.Improve constantly and forever the system 0f production and service Deming stresses
the importance of continuous improvement or what came to be known as Kaizen.
Quality is built in through improvements in the design of the products, processes and
systems.
6. Institute training There should be basic foundation of training for the managers the
new employee. The greatest waste in India is in not using the abilities of people
7. Adopt and institute leadership As Deming put it: ‘The job of management is not
supervision, but leadership. Quality and productivity cannot come about in a leadership
vacuum' .
8. Drive out fear In order to have improvements in quality and productivity, it is essential
that people feel secure. Fear only gives rise to impaired performance, pad del figures and
lack of initiative. Fear makes people think only in short-term at the cost a long-term
result.
10. Eliminate slogans, exhortations, and targets for the work force As Goethe observed,
'Where an idea is wanting, a word can always be found to take its place'. Slogans, posters
and exhortations are directed at the wrong people. The charts and posters take no account
of the fact that the most trouble comes from the system for which the management is
responsible. Also, numerical goals set for people, without a road map to reach the goal,
have effects opposite to the effects sought.
11. Eliminate numerical quotas for the work force and numerical goals for
management According to Deming, a quota is a fortress against improvement of quality
and productivity. The job of management is to replace work standards by knowledgeable
leadership.
12. Remove barriers that rob people of pride workmanship People always want to do a
good job and be proud of it-be they workmen or managers. However, in many
organizations people-whether in management or the shop floor-have become, to
management, a commodity.
We have discussed some aspects of TQC and it can be seen that there are four
characteristics of the engineered total quality system that are of particular importance:
First, and most important, it represents a point of view for thinking about the way
quality really works in a modern business company or governmental agency and how
quality decisions can best be made. This point of view is of the major quality activities as
continuous work processes, they start with the customer's requirements and end
successfully only when the customer is satisfied with the way the product or service of
the enterprise meets these requirements.
These are processes in which it is important for quality both how well each person,
each machine, and each organization component works individually and how well they
all work together. In these processes in a manufacturing business, for example, the best
quality-control decision is not merely the historically usual one which is based upon
conformance of the product with certain engineering specifications-important as this is in
itself. It is, more fully, also the decision, which is based upon the satisfactory quality of
the product with reference to total customer expectations.
The second characteristic of the engineered quality system is that it represents the basis
for the deeply thought-through documentation not merely of a thick book of details but
the identification of the key, enduring quality as the integrated people-machine-
information relationships, which makes a particular activity viable and communicable
throughout the firm. It is the specific way in which the manager, the engineer, and the
analyst can visualize what, where, when, why and how of his and her quality work is
making as it affects the total scope of plant or company quality.
Each person can visualize her and his own work assignments and decision making
responsibilities in a quality activity, the quality work and in which he or she has a
relationship, the relevant quality work an made by others, the machine interfaces, and the
information inputs. The systems approach thus represents the way in which quality
becomes a reality for the work force of the plant or company as a living part of working
life.
Third, the quality system is the foundation for making the broader scope of quality
activities of the company realistically manageable because it management and employees
of the plant and company to get their around their customer-requirements and convert it
customer-satisfaction qualities. Moreover, quality systems provide alternatives, under
given quality situations, which provide a management base designed to have the full
participation of human resources of the company, to be measurable, and to have the
feedback of actual results.
The fourth characteristic of total quality system is that it is the systematic engineering
of improvements through quality activities of the company. Here a change in a key point
of quality work any where in the customer to-customer activities, the total quality system
provides framework and discipline so that these individual changes may be engineered
for their degree of improvement of the total quality activity itself.
Let us now focus on how effectively one must organize for quality.
We have seen that total quality control guides and coordinates the actions of people,
machines, and information across the whole range of key company activities, it is
essential that quality be organized effectively and economically company wide.
There are three considerations in the development and operation of this total quality
organization. The first is the identification and confirmation of the specific quality work
and team work- including the responsibility, authority, accountability, and relationships
for quality-of each of the key individuals and groups in the company and the plant.
The second consideration is the identification and confirmation of areas for the quality-
control function itself so that it may help the company achieve its quality objectives.
The third consideration is the leadership of company and plant management itself in the
establishment and ongoing maintenance of quality organization.
The American Managers were proudly pointing out to me the spacious, well equipped
and well staffed quality inspection section at the end of the assembly line. I wondered
why they needed such an elaborate quality inspection station if they made their products
properly in the first place. I told my workers to properly and carefully complete the
assigned jobs, and not send any slipshod work down the assembly line. In this way we cut
down the defect rate drastically.
Friends, now I would like to focus on how to stop work \ line operation in case
of any problem.
ANDON / JIDOKA
A visual control reduces errors and waste by making problems visible. It identifies the
gap between the standard and actual performance and tells us how to respond.
House Keeping
It is because
1) employees feel good if the work place is clean
2) searching is avoided
3) time wasted in handling reduced.
4) no unnecessary supplies
5) less rejection/rework
6) better preventive maintenance
7) less equipment downtime
8) more usable space
9) passage ways are neat and clean'
10) abnormalities noticed at a glance
11) eliminates accidents
12) productivity improvement
HOUSE KEEPING is
"5S" There are 5 Principles of housekeeping, also known as “5S”. It is easy to remember
C Cleanliness (Beiso ).
A Arrangement \ organization (Seiri )
N Neatness (Seiketsu)
D Discipline (Shitsuke)
O Orderliness: a place for every thing and everything in its place (Seiton).
POKAYOKA
The sources are many for e.g. omitted processing, processing errors, missing and wrong
parts, processing wrong work piece, adjustment error etc. Almost all defects are caused
by human errors. Human errors are usually inadvertent.
Poka yoka devices help to avoid the defects even when inadvertent errors are made.
Pokayoka help build quality into the product. In other words pokayoka is nothing but fool
proofing so that defects don’t occur.
QC are small group activities consisting of 6-12 members from the same work area who
meet regularly for a fixed time to look into the various quality problems, analyses the
problems, seek solutions to the problem and implement the solutions till the problems are
eliminated or reduced drastically. The QC group formation is voluntary. The solutions are
standardized after implementation of the changes. The team gives their presentations
before the Management who suitably reward the team for their efforts.
Here the employees of the company of all level in the organization are trained in the
basic skills such as
• Sampling and Data Collection i.e. Check Sheets
• Brainstorming
• Cause and Effect Diagram
• Pareto Analysis
• Stratification
• Graphs and Charts.
• Histogram
• Scatter Diagram
• Process controls charts. Etc.
The above are the traditional and basic seven tools. These QC tools are used for quality
problems, analysis, solutions and solving their work related problems. Further new seven
tools have emerged for better managerial decisions and building higher quality into the
products for customer delight.
In India, BHEL started its first Quality Circle at its Hyderabad unit in 1980-81. Since
then QC is been implemented in many industries. The results of Quality Circle movement
in India are encouraging. This is due to the firm commitment, continual support and
guidance of the top and senior mangers to the QC. The concept of QC is also spreading in
the non-industrial sectors such as Hospitals, Banks, educational institutions etc. The
Quality Circle Forum of India has been active in the propagation of knowledge, gained
from experience, about the methodology for starting and establishing QC in the Indian
environment.
Causes
Sub causes
Problem
Area
PARETO ANALYSIS HISTOGRAM
…. …. ….. …… UCL
…. … …. ... CL
… … … ...
… … … ... LCL
… … … ...
TAGUCHI PHILOSOPHY.
Our traditional view has been that there is no negative effect as long as the products /
components are within their respective end specifications. The whole Statistical Quality
Control, with its percentage tolerances and the Upper / Lower Control Limits, is based on
this traditional view. In our Statistical Process Control so far we have seen 3-sigma
control limits and 'percent' defectives. As long as the process is within these, the process
was considered to be 'in control' or 'normal' and it was not to be disturbed. Taguchi,
(contrary to this view) says that the point to consider is the cumulative impact of the
deviations target value. Using the Taylor Expansion Series, Taguchi developed a
mathematical "model in a quadratic function of the deviation of the quality of interest
from its target value. The Taguchi Function is shown in the following figure
Taguchi methods of quality control, therefore, involve the on-line and off-line methods.
On-line odds include the use of statistical process control charts amongst others so that
the aspect of red deviations about the target value are taken care of as far as the process
or manufacturing is concerned._ The off-line methods involve market research, product
design and development, and process development.
The tolerances, the key process variables and the overall system need to be so designed
these variations in the end product are minimized. For Taguchi, the variations from the
target values are important, and these variations are to be reduced as much as possible.
While it is necessary to be " rate', it may be better to be 'precise while being inaccurate'
than to be 'accurate but imprecise
For example, between the two hits on the dartboard as shown in Fig below
xxx
The former be preferred; because, although the darts have missed the bull' s eye, with a
correction in the direction of hit, most of the darts will hit the bull' s eye. This cannot be
said of the more variable process.
Quality design is another area in which Taguchi departs from traditional quality
control. Focusing on customers, Taguchi methods place a premium on careful product
design. Thus in addition to quality in production, Taguchi emphasizes quality control in
four other areas i.e. (1) product planning (2) product design (3) process design (4)
production service after purchase.. Products are designed so that they are robust – that is,
so they function under a wide range of environmental conditions without faltering.
With that, we have come to the end of today’s discussions. I hope it has been an
enriching and satisfying experience.