Industrial Engineering Department, Dokuz Eylul University, Turkey JUST IN TIME SYSTEMS Merve Sezen GÜLER 2010503029 Industrial Engineering Department, Dokuz Eylul University, Turkey 22.11.2018 Just-In-Time Systems

Learning objectives : Understanding the theory behind Just-In-Time Understanding the advantages of using Just-In-Time Just-In-Time production systems 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

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 22.11.2018 Just-In-Time Systems

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 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

JIT SYSTEMS; Kanban JIDOKA SMED (Single Minute Exchange of Die) The 5-S System 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

How does the Kanban system work? Production Control Systems How does the Kanban system work? 22.11.2018 Just-In-Time Systems

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. 22.11.2018

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 22.11.2018

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 22.11.2018

“Automation with human intelligence” JIDOKA (Autonomation) “Automation with human intelligence” = AUTONOMATION JI DOU KA JIDOKA 22.11.2018 Just-In-Time Systems

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”. 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

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. 22.11.2018

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 22.11.2018 Just-In-Time Systems

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. 22.11.2018 Just-In-Time Systems

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 22.11.2018 Just-In-Time Systems

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 22.11.2018 Just-In-Time Systems

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