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OBJECTIVES
JIT Defined The Toyota Production System JIT Implementation Requirements JIT in Services
Here Herethe thecustomer customerstarts starts the theprocess, process,pulling pullingan an inventory inventoryitem itemfrom from Final FinalAssembly Assembly Then Thensubsubassembly assemblywork workis is pulled pulledforward forwardby by that thatdemand demand
Customers
Vendor
Vendor
Final Assembly
Sub Fab Vendor
The Theprocess processcontinues continues throughout throughoutthe theentire entire production productionprocess processand and supply supplychain chain
Fab
Vendor
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
The McGraw-Hill Companies, Inc., 2004
These Theseare aresmall smallspecialized specialized plants plantsthat thatlimit limitthe therange range of ofproducts productsproduced produced (sometimes (sometimesonly onlyone onetype typeof of product productfor foran anentire entire facility) facility) Some Someplants plantsin in Japan Japanhave haveas as few fewas as30 30and and as asmany manyas as 1000 1000employees employees
Heat Treat
Lathe
Lathe
Lathe
Press
Press
Press
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Lathe
Press
Heat Treat
Lathe
Press
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Not uniform
Total 9,000
Uniform
Total 9,000
How Howdoes doesthe theuniform uniformloading loadinghelp helpsave savelabor laborcosts? costs?
The McGraw-Hill Companies, Inc., 2004
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WHAT IT REQUIRES
WHAT IT ASSUMES
Employee participation
Industrial engineering/basics Continuing improvement Total quality control Small lot sizes
Stable environment
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Example: By identifying defective items from a vendor early in the production process the downstream work is saved
Paperwork backlog
Inspection backlogs
Decision backlogs
Example: By identifying defective work by employees upstream, the downstream work is saved
The McGraw-Hill Companies, Inc., 2004
14
Withdrawal kanban
Machine Center
Storage Part A
Storage Part A
Assembly Line
Production kanban
The process begins by the Assembly Line people pulling Part A from Storage
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Underutilize capacity
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Backflush
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