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GROUP MEMBERS

Jayshree
Varsha
Melanie
Abhishek
Priyanka
Rekha
Hardik

Case Study of
Manufacturing
Excellence through
JIT Approach

Introduction
Just In Time manufacturing system refers to
approaches initially developed by Taiichi
Ohno, father of Toyota production system
that focuses on elimination of waste in all
forms.
JIT finds its origin in Japan, where it has
been in practice since the early 1970s.
Taiichi Ohno developed this philosophy as
a means of meeting customer demands
with minimum delays.

About JIT

This case study deals with the Just In Time


approach in an industry in the manufacturing
sector.
This proposed work focuses on attaining
manufacturer of Flow, Level, Pressure,
Temperature Measurement & Control Instruments
used for Chemical process, Pharmaceuticals,
Petrochemicals, Power Generation, Oil & Gas, etc.
The goal is to increase the capacity and
throughput rates, reduce leadtimes, system for
simplification, and improve quality and efficiency
while reducing operating costs.
JIT uses tools such as 5S, Layout, Cause and
effect diagram, visual controls, rewards and

Problem Occur:
Cluttered

with scrap and rework parts


Finding parts, tools, and/or raw material
Production efficiency have to be
increased.
Number of operators likely to be exceeds
in the production department.
System for simplifications.
Overtime schedule

Principle of Just in time


The

principle of Just in time (JIT) is to eliminate


sources of manufacturing waste by getting right
quantity of raw materials and producing the right
quantity of products in the right place at the right
time.
The 7 Wastes of Just In Time Manufacturing
1. Waiting
2. Over Production
3. Rejection
4. Excess Motion
5. Over Processing
6. Excess Inventory
7. Transportation

COMPANY USE JIT


SCIENTIFIC

DEVICES (BOMBAY) PRIVATE LIMITED is


an ISO 9001 : 2008 Certified company
PRODUCT:
Flow Measuring Instruments
Level Measuring Instruments
Level Switches & Controllers
Pressure Measuring Instruments
Temperature Sensors
Temperature Indicators Controllers
Sight Flow Indicators
Pipe Line Strainers & Filters
Liquid Density meter & Transmitter

Products - Sight Flow


Indicators
Double Window Sight Glass

A sight Flow Indicator is a device which is inserted in a


run of pipe to observe the flow of fluid in the pipe.

Process of
Production
Step

1: Study of process flow chart of


the product.
Step 2: Layout
Step 3: 5S methodology
Step 4: Identifying bottleneck areas
Step 5: Solution to bottleneck areas.

Before Implementation
Chart

BOTTELNECK

PAINTING

Removing of Chip by tools such as hammer and


chisel.
Red Oxide painting for detections of defects such
as Spots, etc
The addition of thinner in red oxide,will reduce
the time duration by 50%.
Autocatt putty grey is used for leveling minor
defects, while red oxide painting takes 10-15
mins.
Finally Black, Silver or Grey colour is used on the
product depending on the requirement of the
customer.
It is also time consuming process.
Space constraints and non enthusiasm

FILTER DEPARTMENT
Strainer

which is important element


in pipe line it block the impurities.
Spot welding machine is used to
make strainer but this spot welding
machine goes continuous break
down.
It takes more time in processing then
the actual time required.

FOR EXAMPLE
No. of Breakdown No. of Months
this occurred
0

10

Each breakdown cost the firm and average of Rs. 2800 for a cost
of Rs. 1500 per month preventive maintain would be carried down
to limited the breakdown to an average of 1 per month.
We get probability as 0.99
We get month as 1.7
We multiply the breakdown cost with month i.e 2800 * 1.7 = 4760
Preventive cost = 1500 + 2800= 4300

HYDRO TESTING
DEPARTMENT
There

are only 2 hydro testing


equipment so maximum 3-4 product
per hour is hydro tested considering
the strains and efforts of worker.

After Implementation
Chart

Comparing of Both Chart

Difference after
Implementation

CONCLUSIONS
JIT

Manufacturing help to improve the system in


organization.
Management must stay engaged and constantly
challenge employees to improve and develop
higher value added work.
5S were applied by JLT.
Technique was used in painting, filter and hydro
testing department.
Reduction in approximate 275 minutes of
operation time of double window sight flow
indicator.
JIT helps in reduction of waste.

Our Suggestion
Painting:

Spread 2 tool should be use for


Red oxide and different colors. Should
place thing systematic order.
Filter: as machine get breakdown while
producing strainer they can buy new
machine
Hydro Testing : as they already have 2
Hydro test machine by adding one more
machine the trading will increase by 50%
Rewards and incentives