Syllabus

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Syllabus

• I. J.I.T. Introduction
  CHAPTERS 1, 2
• II. Setup Time Reduction CHAPTER 4
• III. Uniform Plant Loading CHAPTER 3
• IV. Kanban CHAPTER 6
• V. Group Technology Layout CHAPTER 5
• VI. J.I.T. Purchasing CHAPTER 7
• VII. T.Q.C. In J.I.T. CHAPTER 8
• VIII. Employee Involvement
• IX. MRP J.I.T. CHAPTER 9
• X. J.I.T. Implementation CHAPTER 10-13

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I. J.I.T. Introduction

• What Is Just -in-Time?
• Or What Is a J.I.T. System?
• Keeping inventory close to zero
• Getting materials just in time when you need them
• Manufacture just what you need for orders
• Decreasing mfg costs
• Create special relationships with your suppliers
• Simplify processes
• Minimize waste
• Reduce cycle time
• Locating suppliers close by
• Lower variance
• Jit primarily used for large scale production
• Production, materials-are processed just in time
  when you need them
• Implement TQM
• MRP VS JIT

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A. Historical Perspective

• J.I.T. System/Philosophy Was Developed by Mr.
  OHNO (Vice President for Manufacturing - Toyota)
• 1960 - 1975 Development
• Incremental Improvement
• Japanese Companies Did Not Begin to Use the
  J.I.T. System Until 1973
• 1979 - 80 Many U.S. Executives (Especially Auto
  Executives, Univ. Professors) Visited Japanese
  Companies. What Was J.I.T.?
• Hewlett - Packard, Xerox, Ford, GM (and Many
  Other Companies) Switched Plants to the J.I.T.
  System.

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B. J.I.T. Definition

• According to Toyota - J.I.T. Philosophy Aims at
  Reducing or Eliminating Waste From Manufacturing,
  Purchasing, Manufacturing Support, and
  Distribution Activities.
• Key Word Waste
• Toyota Definition Anything Other Than the
  Minimum Amount of Equipment, Materials, Parts,
  and Working Time Absolutely Essential to
  Production.
• U.S.A. Definition Anything That Does Not Add
  Value to the Product, Is Waste.

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Definition of Waste

• Example Purchasing an Item in an Organization
• Contact Suppliers
• Ask for Bids
• Choose One (Lower Price/Schedule/Quality)
• Place an Order
• Receive Shipment
• Inspect
• Update Records
• Transport and Stock Item----supplier supplies at
  the user site
• User Comes to Storeroom
• Update Records
• Move Materials to User
• Receive Invoice BACKFLUSHING
• Match Receipt, Invoice, Inspection
• Authorize Payment

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Definition of Waste (Contd.)

• All Wasteful Under J.I.T.
• Material Delivered to Machine That Will Process
  It
• Getting Rid of Accounts Payable - Backflushing
• Send a Check for Parts Purchased Based Upon
  Product Shipped
• Productive - Changing Material Physically.

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C. Another Definition of J.I.T. J.I.T. Ratio -
for Those Quantitatively Minded
Lot size 500 Component XYZ Unit Time C 1
min. M 2 min. D 1 min. A. 1 min.
Lead time - 115 hours Setup queue production
J.I.T. Ratio
Lead time - 115 (60) 1380 Work content
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Ideal 1 to 2 Good 3 to 4 Bad anything else
C M D A
Eliminate setup time lot size 1 Change layout
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D. View of Inventory in J.I.T.

• Traditional
• Typical Manufacturing - a Large Amount Necessary
  in Front of Work Centers.
• Why? Setup Time
• Safeguard Against Breakdown (Feeding Machine)
• Safeguard Against Quality Problems
• Safeguard Against Absenteeism

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E. Basics of J.I.T., S.P.C. Emerged in U.S.
(J.I.T. - Refinement /Evolution From Scientific
Management)

• Model T in 1926

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F. J.I.T. Going Back to Basics (ABCs) of
Production Management

• Making Useful Product - Minimum Cost. - High
  Quality - Minimum Time

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G. Components of J.I.T.

• What Does This Mean?
• How Does It Differ From Traditional
  Manufacturing?
• What Kinds of Wastes Are Reduced/Eliminated by
  This Technique?

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H. Benefits of a J.I.T. System