SISTEM PRODUKSI TEPAT WAKTU (JUST-IN-TIME PRODUCTION SYSTEMS) Roesfiansjah Rasjidin Teknik Industri – Fakultas Teknik Universitas Esa Unggul

Penilaian Akhir UAS: 35% UTS: 30% Tugas/Quiz: 15% Kehadiran: 10% Partisipasi kelas: 10%

Rencana Perkuliahan Asal, tujuan & definisi JIT Keuntungan, perbandingan dgn sistem konvensional, dan skema JIT Konsep 5S dan persiapan sumberdaya manusia Sistem Tarik dan Sistem Dorong Sistem Kanban Produksi Lot Kecil Reduksi Waktu Set-up SMED dan Teknik Reduksi Waktu Set-up Pemeliharaan dan perbaikan mesin dan peralatan Teknologi kelompok dan sel manufaktur Screening, pokayoke & jidoka Leveling production Sinkronisasi dan penyeimbangan proses

PENGANTAR History and Origins of JIT Definition and Objectives of JIT JIT Benefits and Success Factors Comparison: Conventional vs JIT Systems JIT Scheme

Origins of Just-in-Time JIT originated in Japan, post WWII Driven by a need survive after the devastation caused by the war JIT gained worldwide prominence in the 1970s Japanese firms, particularly Toyota, in 1970's and 1980's © Wiley 2007

Origins of JIT (cont’d) Taiichi Ohno and Shigeo Shingo Geographical and cultural roots Japanese objectives “catch up with America” (within 3 years of 1945) small lots of many models Japanese motivation Japanese domestic production in 1949 – 25,622 trucks, 1,008 cars American to Japanese productivity ratio – 9:1 Era of “slow growth” in 1970's

Waste: Time, Material & Resources Bad design Machine downtime Unreliable supplier Poor quality Inefficient layout

Waste Elimination Ohno devised a new system of production based on the elimination of waste. Waste was eliminated by: just-in-time - items only move through the production system as and when they are needed autonomation - automating the production system so as to include inspection - human attention only being needed when a defect is automatically detected whereupon the system will stop and not proceed until the problem has been solved

JIT Objectives Ultimate objectives: Zero Inventory. Zero lead time. Zero failures. Flow process. Flexible manufacture. Eliminate waste.

JIT Definition Just-in-time (JIT) is defined in the APICS dictionary as “a philosophy of manufacturing based on planned elimination of all waste and on continuous improvement of productivity”.   It also has been described as an approach with the objective of producing the right part in the right place at the right time (in other words, “just in time”).  

JIT Benefit Summary Improvement Aggregate percentage (3-5 years) Annual percentage Manufacturing cycle time reduction 80-90% 30-40% Inventory reductions: Raw materials 35-70 10-30 Work-in-process 70-90 30-50 Finished goods 60-90 25-60 Labor cost reductions: Direct 10-50 3-20 Indirect 20-60 3-20 Space requirements reduction 40-80 25-50 Quality cost reduction 25-60 10-30 Material cost reduction 5-25 2-10

Just-in-Time Success Factors Suppliers Preventive Maintenance Layout Inventory Scheduling Quality Employee Empowerment JIT

Three Elements of JIT © Wiley 2007

JIT and Competitive Advantage JIT Requires:

JIT and Competitive Advantage Which Results In: Which Yields:

Comparison: Conventional vs JIT Systems

Just In Time Scheme