ApEc 4821

Eidman

Just in Time Systems

What is JIT?
An integrated set of activities designed to achieve high-volume
production using minimal inventories (raw materials, work in progress, and
finished goods).
- It attempts to eliminate waste (anything that does not add value to
the product).
- It attempts to use the full capacity of the workers.

Elements of JIT Systems
1. Stabilize the master schedule

a. The master schedule indicates the amount of various products
that are to be produced for the month. This production is
scheduled to create a uniform load on all work centers.

Example: What is the daily production quantity and sequence for
the monthly requirements of 5000 A, 2500 B, and 3000 C?
Assume there are 20 working days during the month.

Daily schedule

The sequence is determined by dividing each daily requirement by
the largest common multiple - in this problem.

The sequence is
The number of runs per day is

b. Production is leveled to create a uniform load.

c. The sequence presumes zero changeover costs to shift from A
to B to C.

d. The work center only produces the daily quota and stope for the
day. The remaining time is used for maintenance. Overtime is
worked if the quota has not been reached by the end of the shift.

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2. Kanban System
a. A subsystem of JIT used to control the sequencing of jobs
through a sequential process.
b. Two major type of Kanban cards are used to control the flow
of parts.
- production cards
- withdrawal cards











c. How does the system work? (Figure 17.3 in Schroeder)
- When the container is full of parts at work station A, it
is taken to work station B where the parts are used.
- When the container is emptied at B, it is returned to A
which is authorized to produce another container
of parts.
d. How many Kanban cards (containers) do we need?

n = DT/C
where
n = total number of containers
D = demand rate of the using work center
C = container size in number of parts
T = time for a container to complete an
entire circuit.

Maximum inventory = nC = DT





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d. Example: A company is in the business of maching parts
that go through various work centers. Suppose work center
A feeds work center B with parts.The following time (in
minutes) are given for each work center.
Work Center
A B
Set up Time 3 2
Run Time (per part) 0.5 0.1
Move time 6 8

A standard Kanban container holds 50 parts that are
transferred from work station A to work station B. The
demand rate at work center B is four parts per minute.
How many Kanban containers are needed in this
situation? What is the maximum inventory?






3. Reduce set-up time and lot sizes
a. Reducing set-up time increases available capacity and makes
it possible to reduce Kanban cards and thus inventory.
b. Reducing set-up times reduces lot sizes.


4. Layout of Equipment
a. The effect of JIT is to reduce lot size and move towards
more automation and set a new streamlined flow.

- See Figure 17.6.
- Pre JIT (part a) Suppliers deliver to a stockroom and parts
are placed in stockrooms after certain stages of production
are completed.

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- When JIT implemented (part b) All stock rooms
eliminated. The stock is kept on the shop floor.
- JIT evolved to Group technology or cellular manufacturing
layout (part c). The work centers have been refined so parts
can flow smoothly. Most of inventory buffers next to each
machine have been eliminated as parts flow from one station
to the next.
b. JIT requires superb maintenance of equipment. Workers take
responsibility for their own maintenance.

5. Effect on Workers
a. To make JIT operate effectively, you need multifunctional
workers.

b. May need to pay workers on a different basis.
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c. Need to engage workers in problem solving activities.

d. Workers must understand their new roles.

6. Effect on Supplier Relations
a. JIT may require more frequent deliveries perhaps several
per day.

b. There is a tendency to use fewer suppliers with JIT.

- Establish long-term relationships to ensure the quality
needed. Typically no inspection when parts or
ingredients are delivered.

- One supplier often supplies a large number of parts or
ingredients.

- Deliveries made to the production lines.

Comparison of MRP and JIT

1. JIT works very well in a pure repetitive manufacturing situation
where the master schedule is the same from day to day and level
loaded.

2. Job shop, batch oriented and non-repetitive manufacturing should
use MRP.

3. Systems that change from time to time but are repetitive within a
fixed time period can use an MRP system to predict the
requirements and capacity utilization for a new work plan when a
major change is about to occur. Then a JIT system can be used
within the level production periods.

4. MRP assumes the present system is correct and seeks to make the
best of that system. JIT seeks to change the system to make it
better.


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