1. Industrial Engineering Department, Dokuz Eylul University, Turkey
JUST IN TIME SYSTEMS
Merve Sezen GÜLER
Industrial Engineering Department, Dokuz Eylul University, Turkey
Just-In-Time Systems

2. Learning objectives : Understanding the theory behind Just-In-Time
Understanding the advantages of using Just-In-Time
Just-In-Time production systems
Just-In-Time Systems

3. What is Just-In-Time ? Just-In-Time (JIT) is an easy concept
to understand.
If you think about someone's journey to work,
they could leave the house just-in-time to get
to the bus station, just-in-time to catch the bus,
which would get them to their place of work
just-in-time, allowing them to be at their desk
just-in-time to start work.
Just-In-Time Systems

4. What is Just-In-Time ?
Just-In-Time (JIT) is a collection of techniques used to improve operations.
JIT is a manufacturing philosophy which eliminates waste associated with time, labour and storage space.
In engineering, using the just-in-time theory would allow the components that are needed to produce a product to be delivered to the worker, just-in-time.
The products can then be made available for the customers just-in-time.
Just-In-Time Systems

5. What is Just-In-Time ? What is Just-In-Time ?
This process allows for all types of stock, including materials and finished products, to be eliminated.
Implementing a just-in-time structure can mean a company is adopting a lean production system.
Just-In-Time Systems

6. Basics of the JIT;
The company produces only what is needed, when it is needed and in the quantity that is needed.
The company produces only what the customer request, to actual orders, not to forecast.
JIT can also be defined as producing the necessary units, with the required quality, in the necessary quantities, at the last safe moment.
It means that company can manage with their own resources and allocate them very easily.
Just-In-Time Systems

7. Why use Just-In-Time?
There are several aspects in engineering processes that are often deemed as wasteful, which can be eliminated using a JIT approach.
These include:
Time spent waiting
Over production
Inventory
Just-In-Time Systems

8. Work in process inventory level
Figure 1
Work in process inventory level
hides the problems
inventory
Unreliable
Vendors
Capacity
Imbalances
Scrap
Inventory is like water in a stream
Rocks are like problems
Just-In-Time Systems

9. Figure 2 Reducing inventory makes problems very visible
Unreliable
Vendors
Capacity
Imbalances
Scrap
Reducing inventory makes problems very visible
Reducing inventory reveals problems to be corrected.
Just-In-Time Systems

10. JIT SYSTEMS; Kanban JIDOKA SMED (Single Minute Exchange of Die)
The 5-S System
Just-In-Time Systems

11. KANBAN Production Control Systems Kanban is a Japanese word for card.
Kanban is a method for implementing JIT.
In order to produce, you need both;
- material to work on
- an avaliable Kanban.
Each work station has a fixed kanbans.
Just-In-Time Systems

12. How does the Kanban system work?
Production Control Systems
How does the Kanban system work?
Just-In-Time Systems

13. KANBAN Production Control Systems Flow of work 2 3
Worker 2 finishes a part, outbound moves over
2 has a green tag available, so 2 gets another part to work on:
2 takes off 1’s pink tag giving it back to 1, and
puts on his green tag and moves it into position.

14. KANBAN Production Control Systems Flow of work 2 3
When 3 finishes a part,
Finished parts move over one spot
He has to have a blue tag available to put on,
He gets a part from 2’s outbound pile,
And gives the green back to 2
3’s production will be taken by 4, offstage right.
Tag goes back into 3’s bin

15. KANBAN Production Control Systems 2 3 2 3 Blue finishes his part next.
But 4 hasn’t freed up any of the blue kanbans, so there is nothing for 3 to work on now.
3 could maintain his machine, or see if 4 needs help 2 3

16. “Automation with human intelligence”
JIDOKA
(Autonomation)
“Automation with human intelligence” =
AUTONOMATION
JI DOU KA
JIDOKA
Just-In-Time Systems

17. JIDOKA (Autonomation)
Jidoka is providing machines and operators the ability to detect when an abnormal condition has occurred and immediately stop work.
Jidoka is one of the two pillars of the Toyota Production System along with just-in-time.
Jidoka is sometimes called autonomation, meaning “automation with human intelligence”.
Just-In-Time Systems

18. JIDOKA (Autonomation) Jidoka helps to detect a problem earlier.
Jidoka avoids the spread of bad practices.
No defective products produced.
There is a tremendous improvement in productivity.
Just-In-Time Systems

19. Improvements are incorporated into the workflow.
JIDOKA
(Autonomation)
Automation
detects
a problem
A problem
interrupt
the workflow
Figure 3
Concept of JIDOKA
The problem
is fixed.
Work is
Stopped.
Improvements are incorporated into the workflow.

20. Single Minute Exchange of Die
Reducing the setup time is an important precondition for increasing the flexibility and the capacity of a production line.
SMED is a method used to analyse and reduce setup times.
Setups that took hours could be reduced to minutes.
SMED
Single Minute Exchange of Die
Just-In-Time Systems

21. Single Minute Exchange of Die
SMED
Single Minute Exchange of Die
The SMED method consists of 3 steps ;
Seperate internal and external activities.
Convert internal activities into external activities.
Eliminate and/or reduce all activities (Internal and external)
External :
Activities while machine is stopped.
Internal :
Activities while machine is running.
Just-In-Time Systems

22. Workplace organization and standardization
The 5-S system is developed in Japan.
The 5-S system is a series of activities designed to improve workplace organization and standardization.
A well organised workplace motivates people. Efficiency and quality increase.
The 5-S SYSTEM
Workplace organization and standardization
Just-In-Time Systems

23. Workplace organization and standardization
The 5-S SYSTEM
Workplace organization and standardization
All of these 5 activities begin with letter ‘S’. They include;
Seiri (Sort) : Remove all unneeded items.
Seiton (Set In Order) : Organize, identify and arrange everything in a work area / space
Seiso (Shine) : Clean everything, use cleaning as inspection.
Seiketsu (Standardize) : Implement visual displays and controls
Shitsuke (Sustain) :
Maintaining what has already been achieved accomplished
Just-In-Time Systems

24. THANK YOU
FOR
YOUR ATTENTION