1. Just-In-Time
“Eliminate Waste”

2. Flexible Resources Multifunctional workers General-purpose machines
Operate more than one machine
General-purpose machines
Machines that were not highly specialized

3. Cellular Layouts Manufacturing cells Often U-shaped
Work flows through cell in one direction and experiences little waiting

4. Pull System
Coordinating production and delivery of materials and parts
Traditionally, inventory has been used as a cushion against lapses in coordination and inventory can be huge
Pull system observed at US supermarkets
Marina Safeway example

5. Pull System Do not order more product than can be used
(or items that can be sold)
Reversal of normal ‘push’ system

6. Kanban Production Control System
Japanese word for ‘card’
Associated with fixed-quantity inventory system
Two-bin system Kanban

7. Small-Lot Production Requires less space and capital
Produces small amounts at a time
Processes can be moved closer together
Transport between stations is simplified
Quality problems are easier to detect
Reveals errors and bottlenecks
HP video

8. Lead Time Processing time Move time
Can be reduced by reducing number of items processed and the efficiency or speed of the worker
Move time
Can be decreased if machines are moved closer together, method of movement simplified, routings are standardized, or need for movement eliminated
Con’t

9. Lead Time Waiting Time Setup Time
Can be reduced through better scheduling of materials, workers, machines and sufficient capacity
Setup Time
Reduction of setup time is important to JIT

10. Quick Setups Separate internal setup from external setup
Internal setup requires the machine to be stopped
External setup can be done while machine is running
Convert internal setup to external setup
Prepare as much as possible in advance (preheating injection mold, standardizing die heights, centering die, etc)

11. Quick Setups Streamline all aspects of setup
Organize workplace properly locating tools near points of use
Keep machines and fixtures in good repair
Simplify or eliminate adjustments
precoding desired settings, using locator pins, etc.
Perform setup activities in parallel or eliminate
Add a person, standardize components, parts, materials

12. Uniform Production Levels
Smoothing production requirements on the final assembly line
Better forecast
Mixed production throughout the day in small quantities

13. Quality at the Source For JIT to work, quality has to be high
No extra inventory to buffer against defective units
Producing poor-quality items and reworking items or rejecting them is wasteful
Workers are responsible for inspection
NEVER pass along defective item

14. Quality at the Source Jidoka Andons Undercapacity scheduling
Authority to stop production line if quality problems were encountered
Andons
Call lights activated by switches
Undercapacity scheduling
Making time to plan, train, solve problems, maintain work environment

15. Quality at the Source Visual control
Quality improves when problems are made visible and workers have clear expectations of performance
Kanbans, andons, process control charts, tool boards, material handling routes clearly marked, demos, instructional photos, performance data

16. Quality at the Source Poka-yoke Kaizen
Foolproof device or mechanism that prevents defects from occurring
Kaizen
Continuous improvement

17. Total Productive Maintenance
Breakdown maintenance
Preventive maintenance
Total Productive Maintenance
Accurate records on time between breakdowns
Frequency of breakdowns
Costs of breakdowns
Determine a preventive maintenance schedule
Employee involvement
Zero defects

18. Supplier Networks
Working with suppliers to improve responsiveness and quality
Trends:
Locate near the customer
Use small, side-loaded trucks and ship mixed loads
Consider establishing small warehouses near to the customer
Use standardized containers and make deliveries according to a precise delivery schedule
Become a certified supplier and accept payment at regular intervals rather than upon delivery

19. Benefits of JIT Reduced inventory Improved quality Lower costs
Reduced space requirements
Shorter lead time
Increased productivity

20. Benefits of JIT Greater flexibility Better relations with suppliers
Simplified scheduling and control activities
Increased capacity
Better use of human resources
More product variety