UNIT -4

JIT Introduction
• “a philosophy of manufacturing based on
planned elimination of all waste & on
continuous improvement of productivity”

• a production strategy that strives to improve a

business return on investment by reducing
1. in-process inventory
2. associated carrying costs
Just In Time!!! Air Traffic Control
 Founder of JIT
• Founded by Taiichi Ohno
• A vice president of Toyota
• Basically implemented in
Toyota plant 1950, well
established after 1970
• Well known as Toyota
Production System
 Followers of JIT
• Adopted by General Electrical in the USA in the 1980

• Some companies referred JIT with different names;

– TOYOTA = ‘Toyota System’

– IBM = ‘continuous flow manufacturing’

– HEWLETT-PACKARD = ‘stockless production & repetitive

manufacturing system’

– GE = ‘management by sight’
 Some Statistics …

Comparison GM TOYOTA

Assembly Hours 40.7 Hours 16 Hours

Defects per 100 Hours 130 Defects 45 Defects

Average inventory level 2 Weeks 2 Hours

 JIT Goals…
• Eliminate disruptions
• Make the system flexible
• Reduce set up times & lead time
• Minimize inventory
• Eliminate waste
• Increase productivity
• Give the customer the products they want, when
and where they want them at the minimum cost
 Steps in JIT
• Introduce the speed
design of process, target, use of recourses
– 1000 cars in a month, 500 workers
– 1000 cars in a week, 1500 workers

• Eliminate or Reduce Stock

zero inventory level is ideal

• Examples of KANBAN (Japanese word ‘CARD’)

involves a customer & a supplier
aim = to satisfy the customer’s needs
 Steps in JIT
• Design of Plant
arranging machinery, people & activities

• Reducing & Avoiding set ups & Preventive

Maintenance
so that activity should not stopped

• Simplifying the planning

so that replacement can be possible
 Tools of JIT
• The 7 wastes
• The 5 Ss
• Kanban Inventory
• Visual Control
• Pokayoke
• Kaizen
• Cellular Work Flow
• Standard Work Concept
• Make it Ugly
• Just Do It
The 7 Wastes
Waste according to JIT
 Concluding JIT
• Advantage of JIT
- reduces cost of production
-make service system flexible
-Eliminate waste
- Reduce set-up time
- Makes service system flexible
Disadvantage
- Minimize WIP
- it takes time to establish
- Simplify the process (ATM,
vending machines etc.)
 JIT in Service Industry

- Consistently high quality

(defect free service)
- Standardized work
methods
- Close supplier ties
- Uniform facility loads
(Reservation system)
- Flexible work force
- Automation
Thank You!