Just-in-Time and Lean Systems
Just-in-Time and Lean Systems
Just-in-Time and Lean Systems
Lean Systems
Just-in-Time and Lean Systems
• JIT Defined
• JIT in Services
Just-In-Time (JIT)
Defined
• JIT can be defined as an integrated set of
activities designed to achieve high-volume
production using minimal inventories (raw
materials, work in process, and finished goods).
• JIT also involves the elimination of waste in
production effort.
• JIT also involves the timing of production
resources (e.g., parts arrive at the next
workstation “just in time”).
Exhibit
Exhibit10.1
10.1
JIT Demand-Pull Logic
Fab Vendor
Sub
Fab Vendor
Final
Customers Assembly
Fab Vendor
The Japanese Approach to Productivity
• Imported technologies
• Efforts concentrated on shop floor
• Quality improvement focus
• Elimination of waste
• Respect for people
Waste in Operations
(1) Waste from overproduction
(2) Waste of waiting time
(3) Transportation waste
(4) Inventory waste
(5) Processing waste
(6) Waste of motion
(7) Waste from product defects
Minimizing Waste:
Focused Factory Networks
Coordination
System Integration
Final Assembly
Minimizing Waste:
•
Group Technology (Part 1)
Using Departmental Specialization for plant layout can cause a lot of
unnecessary material movement.
Heat Treat
Grinder 1 2
Saw Lathe Lathe Press
Heat Treat
Grinder
Saw Lathe A B Lathe Press
Minimizing Waste:
Uniform Plant Loading
Suppose we operate a production plant that produces a single
product. The schedule of production for this product could be
accomplished using either of the two plant loading schedules below.
or
• Employee participation
• Industrial engineering/basics • Stable environment
• Continuing improvement
• Total quality control
• Small lot sizes
Exhibit
Exhibit10.4
Minimizing Waste: Inventory 10.4
Hides Problems
Example: By identifying
defective items from a
Machine
downtime vendor early in the
production process the
Scrap Vendor downstream work is
Work in delinquencies Change saved.
orders
process
queues Engineering design Design
(banks) redundancies backlogs
Example: By identifying
Paperwork Inspection Decision defective work by
backlog backlogs backlogs employees upstream,
the downstream work is
saved.
Exhibit
Exhibit10.6
10.6
Minimizing Waste:
Kanban Production Control
Withdrawal kanban
Systems
Storage Storage
Machine Part A Part A Assembly
Center
Line
dL (1 S )
C
dL (1 S ) 5(2)(1.1)
2.75, or 3
C 4
• Subcontractor networks
Flow Process
• Link operations
• Measure SQC
• Enforce compliance
• Fail-safe methods
• Automatic inspection
JIT Requirements: Stabilize
Schedule
• Level schedule
• Underutilize capacity
• Backflush
• Frequent deliveries
• Quality expectations
JIT Requirements: Reduce
Inventory More
• Look for other areas
• Stores
• Transit
• Carousels
• Conveyors
JIT Requirements: Improve
Product Design
• Standard product configuration
• Quality expectations
JIT in Services (Examples)
• Organize Problem-Solving Groups
• Upgrade Housekeeping
• Upgrade Quality