A Brief Overview

History.
Definition.

Fundamental Concepts.
Objectives of JIT.
JIT Techniques.

Evil Inventory.
Advantage & Disadvantage.
Examples of JIT.
Kanban System.

History
Evolved in Japan after World War II, as a result of their diminishing
market share in the auto industry.
Toyota Motor Company- first to implement fully functioning and

successful JIT system, in 1970s (called TPS).

The TPS concept spread to other Japanese manufactures at 1980s.

Over the years, a number of labels, such as: Stockless production, Zero
inventory, JIT, and Lean production.

Definition
JIT is an approach that seeks to eliminate all sources of waste in
production activities by producing the right part at the right place and

at the right time.

Organizes the production process so that parts are available when they
are needed.
Its overarching goal is to enable production of a variety of end items in
a timely and efficient manner.

Fundamental Concepts
Three fundamental concepts of JIT are:
Elimination of waste and variability.
Pull vs push system.
Manufacturing cycle time (throughput time).

Fundamental Concepts (contd)

Elimination of waste and variability such as: Waste of over production.
Waste of waiting.

Waste of transportation.
Waste of Underutilization of Employees.

Waste of Inventory.
Waste of motion.
Waste of making defective products.

Fundamental Concepts (contd)

Pull vs push system: Push system pushes material into downstream workstation regardless of
their requirement.

Pull system is pull the material into downstream workstation to being

produced only when requested.

Push system = made for inventory.

Pull system = made to order.

Fundamental Concepts (contd)

Fundamental Concepts (contd)

Manufacturing cycle time: Is the time between the arrival of raw
materials and the shipping of final product.

JIT helps in reducing the manufacturing cycle

time.

Objectives of JIT
Produce only the products that customer wants.
Produce products only as quickly as possible as customers want to use
them.

Produce products with prefect quality.

Produce products with features only what customer want.
Produce with no waste.

JIT Techniques
Inventory Reduction as a Tool for Improvement.
Supplier Relationships.
Inventory Pull.

Uniform Plant Loading.

Reduced Setup Times.
Shop-Floor Layout.
Preventive Maintenance.

Evil Inventory
Inventory reduction as a tool for improvements.
large inventory usually does not get rid of problems it just hides
them.

Water = Inventory

Material
handling

Poor
training

Traditional systems use

inventory (water) to buffer the
process from problems (rocks)
that cause disruption.
Break
down
s

Material
quality
problems

Long
setups

Evil Inventory (contd)

Lowering the level of inventory is relatively easy to do. However, the
problems that arise must be corrected quickly Otherwise, the
process will flounder.

Material
handling

Poor
training

Material
Break downs quality
problems

Long
setups

Evil Inventory (contd)

JIT systems view inventory as waste and work to lower inventory levels
to expose and correct the problems (rocks) that cause disruption.

Material
handling

Poor
training

Break
down

Material
quality
problems

Long
setups

Advantage of JIT
High quality.

Flexibility.
Reduced setup times.

Reduced need for indirect labor.

Less waste.
Low warehouse cost.
Synchronization between production scheduling and work hour.

Disadvantage of JIT
Time consuming.
No spare product to meet unexpected order.
Supply Shock : If products do not reach on time.

High risk factor.

Examples of JIT
Supermarket.
McDonalds.

Kanban System
Kanban is an information system that is used to control the number of
parts to be produced in every process. Kanban was developed by Taiichi

Ohno, an industrial engineer at Toyota.

Kanban means card or visible record in Japanese & refers to cards
used to control the flow of production through a factory.
Kanban is a pull System.

Kanban System
Type of Kanban :-

Movement Kanban or withdrawal Kanban: which specifies the kind and

quantity of product that the downstream process (customer) may

withdraw., or signals the need to withdraw parts from one workstation and
deliver them to the next workstation. This tool is known as pull Kanban.
Production Kanban: which specifies the kind and quantity of product that
the upstream process (supplier) must produce, or signals that need to
produce more parts. This is also known as push Kanban.

Kanban System
Some Kanban rules are as follows: The earlier process produces items in the quantity and sequence indicated
by the Kanban.
The later process picks up the number of items indicated by the Kanban

at the earlier process.

No items are made or transported without a Kanban.

Always attach a Kanban to the goods.

Kanban System
The Single-Card Kanban System
Kanban card for
product 1
Kanban card for
product 2

Receiving post

Storage
area

Empty containers
Assembly line 1

O2

Fabrication
cell
O3

O1

O2

Assembly line 2
Full containers

Kanban System
The Single-Card Kanban System (contd)
Kanban card for
product 1
Kanban card for
product 2

Receiving post

Storage
area

Empty containers
Assembly line 1
O2

Fabrication
cell
O3

O1

O2

Assembly line 2

Full containers

Kanban System
The Single-Card Kanban System (contd)
Kanban card for
product 1
Kanban card for
product 2

Receiving post

Storage
area

Empty containers
Assembly line 1
O2

Fabrication
cell
O3

O1

O2

Assembly line 2

Full containers

Kanban System
The Single-Card Kanban System (contd)
Kanban card for
product 1
Kanban card for
product 2

Receiving post

Storage
area

Empty containers
Assembly line 1
O2

Fabrication
cell
O3

O1

O2

Assembly line 2

Full containers

Kanban System
The Single-Card Kanban System (contd)
Kanban card for
product 1
Kanban card for
product 2

Receiving post

Storage
area

Empty containers
Assembly line 1
O2

Fabrication
cell
O3

O1

O2

Assembly line 2
Full containers

Kanban System
Number of Kanban's:-

(1 + + )

is the number of b deliveries per a days.

C is delivery delay factor as an indication of replenishment lead time.

REFERENCES
http://www.slideshare.net/WelingkarDLP/just-in-time-system
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http://www.slideshare.net/swatiluthra5/just-in-time-manufacturing-ppt-31477037?qid=56616627-c675-44ec-a25b66c082268e54&v=&b=&from_search=1
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