JUST IN TIME MANUFACTURING CHAPTER 15 JIT manufacturing is defined in many ways, but the most popular in the elimination

of all waste and continuous improvement and productivity. Waste means any thing other than the minimum amount of equipment, parts, space, material and workers time absolutely necessary to add value to the product. If any part of the chain does not add value for the customer, there is waste. Adding value to a product does not mean adding cost. There are some causes of waste in each element of the product cycle: a) Waste caused by poor product specification and design b) Component standardization c) Waste caused in Manufacturing Toyota has identified seven important sources of waste of manufacturing. The first four relate to the design of the manufacturing system and the last three to the operation and management of the system: 1. 2. 3. 4. 5. 6. 7. The process Methods Movement Product defects Waiting time Overproduction Inventory

Poke Yoke, implies the concept of removing faults at the first instance and making a process or product foolproof. Corrective actions should take place immediately after a mistake is made, which implies 100% inspection as soon as an action occurs. This inspection can take three forms: a) Successive check, b)Self-check and c) Source inspection. JIT Environment have many elements and characteristics: 1. 2. 3. 4. 5. 6. 7. 8. Flow manufacturing Process flexibility Total quality management Total productive maintenance Uninterrupted flow Continuous process improvement Supplier partnerships Total employee involvement

Works cells: Products will be in the same family if the use common work flow or routing, materials, tooling, setup procedures and cycle time. Work stations can then set up in the miniature flow lines or work cells. Benefits of the works cells: a) Lead times going through the cell are reduced drastically. b) Production activity control and scheduling are simplified c) Floor space needed is reduced d) Feedback to preceding operations is inmediately.

Process Flexibility, desirable so the company can react swiftly to changes in the volume and mix of their products. Quick changeover requires short setup times. Short setup times also have the following advantages: 1. Reduced economic-order quantity 2. Reduced queue and manufacturing lead time 3. Reduced work in process (WIP) 4. Improved quality 5. Improved process and material flow Total Quality Management (TQM): Quality is important for two reasons. If quality is not present in what supplied to the customer and the product is defective, the customer will be dissatisfied Total production maintenance is , according APICS dictionary, preventine maintenenance plus continuos efforts to adapt modify, and refine equipment to increase flexibility, reduce material handling and promote continuos flow Pull system starsts at the end of the line and pulls products from the preceding operation as needed. The most well known system is the Kanban system Partnering implies a long term commitment between two or more organizations to archive specific goals. There are three key factors in the partnering: 1) Long term commitment 2) Trust and 3) Shared vision Several scheduling factors are influenced by JIT manufacturing:

1. Master scheduling tries to level capacity and JIT tries to level the schedule based on
capacity and material flow. 2. The shorter lead times reduce time fences and make the master production schedule more responsive to customer demand. 3. The JIT system requires a stable schedule to operate 4. Traditionally, weekly time buckets are used MRP is often called a push system, meaning that the material needs are calculated ahead of time (planned order releases) and, assuming there are no significant changes to the plans, pushed out the production system as a production order The Pull System was developed as an alternative to classical push MRP. The underline concept is not to preplan and generate schedules, but instead to react to the final customer order and produce only what in needed to satisfy demand and then only when it is needed. The Kanban System: With shortened lead times a constant goal in JIT, a system is needed to generate the reorder point signal without having to rely on a formal, structured system that could take time to react. The system works very simply: the Kamban signal (often a piece of cardboard) identifies the material to which it is attached. The information on the Kanban will often include: 1. 2. 3. 4. Component parts number and identification Storage location Container size Work center

Kanban Rules: 1. Every container with parts shall have one, but only one Kanban 2. There will be no partial containers stored 3. There will be no production or movement without an authorization in the form of an unattached Lean Production: implies understanding and correctly implementing the major enterprise wide changes required to truly eliminate or significantly reduce waste in the system

WHICH TO CHOSSE SYSTEM WHERE IT WORKS BEST Is very effective in an environment with a great deal of variability and uncertainty WHERE IT IS NOT AS EFFECTIVE MRP has one major disadvantage: It is highly data depend , and the data needs to be both accurate and timely on an on going basis Can quickly fail in a highly volatile environment because of the reactive nature of the system

MRP (ERP)

JIT (KANBAN)

Works best in a highly stable and predicable environment

In operations where the May not be as effective where the THEORY OF constraint can be easily identified constraint cannot be easily identified or CONSTRAINTS or managed managed