1. Pull Manufacturing and Just In Time
Superfactory Manufacturing Excellence Series
Lean Overview
5S & Visual Factory
Cellular Manufacturing
Jidoka
Kaizen
Poka Yoke & Mistake Proofing
Quick Changeover & SMED
Production Preparation Process (3P)
Pull Manufacturing & Just In Time
Standard Work
Theory of Constraints
Total Productive Maintenance
Training Within Industry (TWI)
Value Streams

2. © 2007 Superfactory™. All Rights Reserved.
Contents
Introduction
Background and History
Components and Implementation
Knowledge Check
© 2007 Superfactory™. All Rights Reserved.

3. © 2007 Superfactory™. All Rights Reserved.
Introduction
Just In Time (JIT) is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and cycle time. The process is driven by a series of signals, or Kanban, that tell production processes to make the next part. When implemented correctly, JIT can lead to dramatic improvements in a manufacturing organization's return on investment, quality, and efficiency.
© 2007 Superfactory™. All Rights Reserved.

4. Components and Implementation
Pull vs. Push Scheduling
The Problem of Inventory
Just In Time
Principles
Benefits and Limitations
Implementing JIT
Kanban
Pull Systems
Quality
One Piece Flow
Continuous Flow
Takt Time
JIT and Suppliers
© 2007 Superfactory™. All Rights Reserved.

5. Push Vs. Pull Scheduling
Push Scheduling
traditional approach
“move the job on when finished”
problems - creates excessive inventory
Pull scheduling
coordinated production
driven by demand (pulled through system)
extensive use of visual triggers
(production/withdrawal kanbans)
© 2007 Superfactory™. All Rights Reserved.

6. Inventory Hides Problems
Scrap
Work in process inventory level (hides problems)
Unreliable Vendors
Capacity Imbalances
© 2007 Superfactory™. All Rights Reserved.

7. © 2007 Superfactory™. All Rights Reserved.
The Philosophy of JIT
JIT means getting the right quantity of goods at the right place and the right time
Often termed “Lean Systems”
All waste must be eliminated- non value items
Broad view that entire organization must focus on serving customers
JIT is built on simplicity- the simpler the better
Focuses on improving every operation- Kaizen
Install simple visible control systems
Flexibility to produce different models/features
© 2007 Superfactory™. All Rights Reserved.

8. Elements of JIT Manufacturing
JIT Manufacturing is a philosophy of value-added manufacturing
Achieved by
Inventory reduction - exposes problems
Kanbans & pull production systems
Small lots & quick setups
Uniform plant loading
Flexible resources
Efficient facility layouts
© 2007 Superfactory™. All Rights Reserved.

9. © 2007 Superfactory™. All Rights Reserved.
JIT Tactics
Single Minute Exchange of Dies (SMED)
Statistical Process Control
Use of standard containers
Doable stable schedules with adequate visibility
TAKT-Time
5-S Program
Kaizen Event
Visual control
Flexible workers
Tools at the point of need
Product redesign
Group Technology
Total Productive Maintenance
© 2007 Superfactory™. All Rights Reserved.

10. © 2007 Superfactory™. All Rights Reserved.
JIT and Suppliers
Few
Nearby (if possible)
Repeat business/Longer Term Agreements
Analysis to enable desirable suppliers to become or stay price competitive
JIT Logistics:
Frequent Deliveries/Smaller Quantities
Exact Quantities
Consumption initiates deliveries
Deliveries directly to the point of use
Perfect Parts
Concurrent engineering design practices
© 2007 Superfactory™. All Rights Reserved.