PRODUCTION

PLANNING AND
CONTROL
(MEFB 433)
Dr. Weria Khaksar
Email: weria@uniten.edu.my
Room No. BN-03-08

8- JIT & LEAN

MANUFACTURING

8- JIT and Lean

Manufacturing
Lean Operation: A flexible system that uses
minimal resources and produces high quality
goods or services.
Lean systems are sometimes referred to as Just-intime (JIT) systems owing to their highly coordinated
activities and delivery of goods that occur just as
they are needed.
Just-in-time
(JIT):
A
highly
coordinated
processing system in which goods move
through the system, and services are
performed, just as they are needed.
Lean manufacturing was developed by the Japanese
automobile manufacturer Toyota.
Another example: the General Motors (GM) [1982]
and NUMMI (New United Motor Manufacturing, Inc.)

8- JIT and Lean

Manufacturing
The Toyota Approach:
Muda: Waste and inefficiency. The driving
philosophy.
Kanban: A manual system that signals the
need for parts or materials.
Pull System: Replacing material or parts based
on demand; produce only what is needed.
Heijunka: Variations in production volume lead
to waste.
Kaizen: Continuous improvement of the
system.
Jidoka: Quality at the source. Each worker is
expected to perform ongoing quality assurance.
Poka-yoke: Safeguards built into a process to

8- JIT and Lean

Manufacturing
The goals
systems:

and

building

Waste
represents
Disruptions
have
blocks
of
lean
unproductive
a negative
A
flexibleand
resources
influenceison
the
system
one
eliminating waste
system by
thatfree
is robust
can
up
upsetting
the
resources
and
enough
to of
smooth
flow
enhance
handle
athrough
mix of
products
production.
products,
often
the system,
and
There
are seven
on
a should
daily
they
be
wastes
in thebasis,
lean
and
to handle
philosophy:
eliminated.
1.
Inventory
Disruptions
changes
in are
the
2.
Overproduction
caused
poor
level
ofby
output
3.
Waiting time
quality,
while
still
4. Unnecessary
equipment
maintain
transporting
breakdowns,
balance
and
5.
Processing
changes
to
the
waste
speed.
schedule, and

schedule,
and
6.
Inefficient
work

8- JIT and Lean

Manufacturing
BUILDING BLOCKS: Product Design
Standard parts: the workers have fewer
parts to deal with, and training times and
costs are reduced. Purchasing, handling,
and checking are more routine and lend
themselves to continual improvement. The
processes can be standardized.
Modular Design: an extension of standard
parts. Modules are clusters of parts treated
as a single unit.
Quality: Quality is the sine qua non of lean.
It is crucial to lean because poor quality can
create major disruptions.
Concurrent Engineering: Engineering
changes can be very disruptive to smooth
operations.
Concurrent
engineering

8- JIT and Lean

Manufacturing
BUILDING BLOCKS: Process Design
Small Lot Sizes: In lean philosophy, the
ideal lot size is one unit, a quantity that may
not always be realistic. Benefits:

Setup Time Reduction: Small lots and

changing product
setups.

mixes require

frequent

8- JIT and Lean

Manufacturing
BUILDING BLOCKS: Process Design
Manufacturing Cells:

Quality Improvement:

Production Flexibility:

8- JIT and Lean

Manufacturing
BUILDING BLOCKS: Process Design
A Balanced System:

8- JIT and Lean

Manufacturing
BUILDING BLOCKS: Process Design
Little Inventory Storage:

8- JIT and Lean

Manufacturing
BUILDING BLOCKS: Process Design
Fail-Safe Methods:

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Personnel/Organizational Elements

Workers as assets:

Cross-trained workers:

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Personnel/Organizational Elements
Continuous improvement:

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Personnel/Organizational Elements
Cost accounting:

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Personnel/Organizational Elements
Leadership/project management:

8- JIT and Lean

Manufacturing
BUILDING BLOCKS:
Control
Level loading:

Manufacturing

Planning

and

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Planning and Control
Pull systems:

Manufacturing

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Planning and Control
Visual systems:

Manufacturing

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Manufacturing
Planning and Control
Limited work-in-process (WIP):

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Manufacturing
Planning and Control
Close vendor relationship:

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Manufacturing
Planning and Control
Reduced transaction processing:

8- JIT and Lean

Manufacturing
BUILDING
BLOCKS:
Manufacturing
Planning and Control
maintenance
and
Preventive
housekeeping:

8- JIT and Lean

Manufacturing
JIT II: In some instances, companies
allow
suppliers
to
manage
restocking of inventory obtained
from the suppliers. A supplier
representative works right in the
companys plant, making sure there
is an appropriate supply on hand.
The term JIT II is used to refer to
this practice. JIT II was popularized
by the Bose Corporation. It is often
referred to as vendor-managed