Just In Time Manufacturing (Part 2)

Just In Time (JIT)
OBJECTIVE: change the manufacturing system gradually rather than drastically.

  1. To be more responsive to customers
  2. To have better communication between department and suppliers
  3. To be more flexible
  4. To achieve better quality
  5. To reduce product cost

JIT control system is only effective in JIT environments. Manufacturing environments can be changed to make planning and control systems simpler and more effective.

JIT PHILOSOPHY
  • Elimination of waste
  • Continuous improvement/ One less at a time (gradually)/ Business Process Re-Engineering (BPR)
  • Problems as opportunities, JIT exposes problem rather than covering them
  • Quality at the source, Quality comes from the stage of design
  • Simplification, Simplicity is a key to successful manufacturing.
  • Visual Control (Tools/ Barcode Robotic)
  • Focus on Customer Needs (Only values in customer's eyes are real values)
  • Production to Customer Demand (without customer demand, there should be no production, only immediate demands are produced)
  • Respect for Individual (Each individual is an important asset)

JIT as an environment
  • Repetitive Manufacturing
  • Total Quality Management (TQM)
  • Total Productive Maintenance (TPM)
  • Total Employee Involvement (TEI)
  • Supplier Partnership

JIT as a Control Technique
  • Pull System
  • Uniform Loading
  • Production Card
  • Synchronized Production

Repetitive Manufacturing


The production of discrete items in a production line with fixed routings. The manufacturing environment is MTO (make-to-order) or ATO (assemble-to-order).  The product is standard or made from standard modules. Materials flow from workstations to the next at a relatively constant rate. Workstations located close together and in sequence. Normally the capacity of the production line is kept sufficient.

Total Quality Management (TQM)


Management approach used to achieve quality improvement and long-term success through customer satisfaction. TQM is meant to improve the quality of all processes, products, services, operations, and corporate culture.

TQM follows PDCA cycle (Plan - Do - Check - Action). In the PDCA cycle, the steps are not necessarily followed strictly sequentially.
  • Plan --> the problem is defined, the symptoms are explained, and the performance measures are determined.
  • Do --> The cause of symptoms is identified and also investigated until the root cause is uncovered. Then the approach to solving a problem is developed and implemented. 
  • Check --> The effectiveness of the proposed approach is observed by using performance measures.
  • Action --> the results are studied to determine what was learned and what can be predicted. The improvement process is standardized to apply to a similar problem.

Deming Cycle

Total Productive Maintenance (TPM)

Means "preventive maintenance" and continuing efforts to adapt, modify, and refine equipment in order to increase flexibility, reduce material handling, and promote continuous flows. It is operator oriented maintenance involving all qualified employees in all maintenance activities.

Total Employee Involvement (TEI)


Elimination A successful JIT Environment should have the cooperation and involvement of everyone in the organization. Traditionally, operators take orders from management and do what they ask to do, while management is in charge of planning, supervising, inspecting, etc. In JIT environment, operators take responsibilities to control equipment, inspecting the quality, correcting the deviations, maintaining the machines, and improving the process. Many duties traditionally are done by the management become the duties of the line workers under JIT. The manager is not playing the game: they are coaches and the line workers are the players. The mission of the coach is to train the player.

Supplier Partnership


In order to establish a smooth flow of materials into the factory, a close and reliable relationship with the suppliers is very important. Relationship with suppliers should be based on mutual trust, cooperation, and long-term commitment.

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