1. PRODUCTION & OPERATIONS MANAGEMENT Module II JIT & LEAN PRODUCTION Prof. A.Das, MIMTS

2. What is JIT ? Producing only what is needed, when it is needed A philosophy An integrated management system JIT’s mandate: Eliminate all waste

3. Basic Elements of JIT 1.Flexible resources 2.Cellular layouts 3.Pull production system 4.Kanban production control 5.Small-lot production 6.Quick setups 7.Uniform production levels 8.Quality at the source 9.Total productive maintenance 10.Supplier networks

4. Waste in Operations

6. Flexible Resources Multifunctional workers General purpose machines Study operators & improve operations

7. Cellular Layouts Group dissimilar machines in manufacturing cell to produce family of parts Work flows in one direction through cell Cycle time adjusted by changing worker paths

8. Manufacturing Cell with Worker Routes Worker

9. Worker Routes Lengthened as Volume Decreases

10. The Pull System Material is pulled through the system when needed Reversal of traditional push system where material is pushed according to a schedule Forces cooperation Prevent over and underproduction

11. Kanban Production Control System Kanban card indicates standard quantity of production Kanban maintains discipline of pull production Production kanban authorizes production Withdrawal kanban authorizes movement of goods

12. A Sample Kanban

13. Types of Kanbans

16. Kanban Square  Marked area designed to hold items Signal Kanban  Triangular kanban used to signal production at the previous workstation Material Kanban  Used to order material in advance of a process Supplier Kanbans  Rotate between the factory and suppliers

17. Determining Number of Kanbans

18. Determining the Number of Kanbans

19. Small-Lot Production  Requires less space & capital investment  Moves processes closer together  Makes quality problems easier to detect  Makes processes more dependent on each other

20. Inventory Hides Problems

21. Lower Levels of Inventory Expose Problems

22. Kaizen Continuous improvement Requires total employment involvement Essence of JIT is willingness of workers to  Spot quality problems  Halt production when necessary  Generate ideas for improvement  Analyze problems  Perform different functions

23. Total Productive Maintenance (TPM) Breakdown maintenance  Repairs to make failed machine operational Preventive maintenance  System of periodic inspection & maintenance to keep machines operating TPM combines preventive maintenance & total quality concepts

24. TPM Requires Management to: Design products that can be easily produced on existing machines Design machines for easier operation, changeover, maintenance Train & retrain workers to operate machines Purchase machines that maximize productive potential Design preventive maintenance plan spanning life of machine

25. Benefits of JIT

26. JIT Implementation Use JIT to finely tune an operating system Somewhat different in USA than Japan  JIT is still evolving  JIT isn’t for everyone

27. JIT In Services Competition on speed & quality Multifunctional department store workers Work cells at fast-food restaurants Just-in-time publishing for textbooks Construction firms receiving material just as needed