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    5 TQM - Jit

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    Bob Bin
    Total Quality Management discusses just-in-time manufacturing and its tools for eliminating waste. Key aspects of JIT include producing only what is needed when it is needed using a pull system, reducing setup times, standardizing processes, and continuously improving quality through techniques like poka-yoke and kanban scheduling. JIT aims to minimize inventory and lead times by synchronizing production across suppliers and within companies.

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    5 TQM - Jit

    Uploaded by

    Bob Bin
    66 views26 pages
    Total Quality Management discusses just-in-time manufacturing and its tools for eliminating waste. Key aspects of JIT include producing only what is needed when it is needed using a pull system, reducing setup times, standardizing processes, and continuously improving quality through techniques like poka-yoke and kanban scheduling. JIT aims to minimize inventory and lead times by synchronizing production across suppliers and within companies.

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    5 TQM_JIT

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    Total Quality Management discusses just-in-time manufacturing and its tools for eliminating waste. Key aspects of JIT include producing only what is needed when it is needed using a pull system, reducing setup times, standardizing processes, and continuously improving quality through techniques like poka-yoke and kanban scheduling. JIT aims to minimize inventory and lead times by synchronizing production across suppliers and within companies.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    66 views26 pages

    5 TQM - Jit

    Uploaded by

    Bob Bin
    Total Quality Management discusses just-in-time manufacturing and its tools for eliminating waste. Key aspects of JIT include producing only what is needed when it is needed using a pull system, reducing setup times, standardizing processes, and continuously improving quality through techniques like poka-yoke and kanban scheduling. JIT aims to minimize inventory and lead times by synchronizing production across suppliers and within companies.

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    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 26

    Total Quality Management

    JIT Manufacturing through Waste Elimination

    Seven Basic Types of Waste


    1. 2. 3. 4. 5. 6. 7. Transportation waste Process Waste Inventory Waste Waste of motion Waste from product defects Waiting time Overproduction

    Common Causes of Waste


    Layout Long setup time Incapable processes Poor maintenance Poor work methods Lack of training

    Just In Time

    Developed by Taiichi Ohno, Former President of Toyota Motor Co. of Japan Taiichi Ohno IBM Continuous flow manufacture Shewhart Hewlett-Packard Stock-less production GE Management by sight Boeing Lean manufacturing Motorola Short cycle manufacturing Japanese The Toyota Production System manufacturers Zero inventory Other terms Synchronous manufacturing Material as needed Kan-ban system

    Crosby Feigenbau m Ishikawa Taguchi Shigeo Shingo

    JIT Definition
    JIT is an approach that seeks to eliminate all sources of waste in production activities by providing the right part at the right place at the right time
    JIT means: Producing the quantity of units that is needed, no more, no less Producing them on the date and at the time required, not before and not after That a supplier delivers the exact quantity demanded, at the scheduled time and date

    Concepts of JIT
    Elimination of Waste and Variability
    Waste: Anything that does not add value Products stored, waiting in queue and defective products Variability: Any deviation from the optimum process that delivers perfect product on time, every time

    Pull versus Push system


    Pull System for JIT

    Manufacturing cycle time (or throughput time)


    Time between the arrival of raw materials and the shipping of finished products JIT helps in reducing this time

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    What is Kanban?
    Japanese Word: Card or Visible Record 1. Production Kanban 2. Conveyance/ Withdrawal Kanban

    Toyota Kanban System


    Physical control system consisting of cards and containers Means of communicating within, to and from a work centre Replace all written work orders, move tickets and routing sheets

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    SMED
    Single Minute Exchange of Dies
    Ex. auto plants - change dies or tools: U.S. 4 4 hours - 4 Japan (Toyota) 1 - 4 minutes 1 4 Setup Time

    Single digit Setup (Minutes)

    One touch Setup (<4 minute to change)

    SMED
    Setup reduction Elements Internal Setup
    Setup while machine idle

    External Setup
    Setup while machine busy

    Adjustment
    Run-ins, calibration

    SMED Process
    Study current process
    As is

    Video tape Convert internal to external setup Eliminate the need for Adjustment Eliminate need for fastening Goal
    Setup time < 10 minutes

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    The 5-S Method


    Seiko - Sort ( Proper arrangement ) Seiton - Stabilize ( Systematic or Orderliness ) Seiso - Shine ( Sweep or clean-up ) Seiketso - Standard ( Personal cleanliness ) Shitsuke - Sustain ( Self-discipline )

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    Quality at Source
    Targeting efforts to improve quality at the activities that produce it Forces every person involved in a conversion process to recognize his/her role as a supplier to one or more internal or external customers

    3 Techniques
    Jidoka
    Autonomation

    Stop and Fix/ Line Stop System Andons/Trouble System

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    Standardization/Simplification
    Eliminate inherent sources of variance Eliminate opportunity for human discretion error Cycle of Improvement
    Standardize

    Implement new methods

    Expose problems

    Solve problems

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

    Supplier Partnerships
    Reliance on suppliers for
    Problem solving expertise Quality at the source Timely communication Participants in cost reduction programs

    Tools of JIT
    Kanban system or Pull Scheduling Set up Reduction (SMED) Lean Production Poka-Yoke Quality at the source Standardization and Simplification Supplier Partnerships Reduced transaction processing Kaizen (Continuous improvement)

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