Think of a company as a pipeline with raw materials entering at one end and products emerging at the other.( the pipe can be extended conceptually with customer needs or orders going in at one end and products arriving to customers at the other.)
The goal is to minimize the through put time, that is to move the materials as quickly as possible Shorter throughput time is better But the pipeline varies in size and has obstructions through out. Output is determined by the narrowest part of the pipeline and the biggest obstruction.
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These must be identified and then eliminated to achieve the goal. As each obstruction is eliminated the flow speeds up but only by as much as allowed by the next biggest obstruction elsewhere in the pipeline.
Identification and location of these obstructions, understanding them, and finding ways to eliminate them are the purposes of JIT and TQM. The pipeline analogy may give an impression those barriers to flow / production, once removed is gone forever. This is not true. To identify the obstruction and its precise location in itself is difficult and time consuming
Inventory as a way of avoiding problems
Sources of obstructions keep changing and it could be any one of the factors of production and /or in any combination of the factors. One gets eliminated and another one crops up and therefore it has got to be continuously attended to.
The pipeline itself and the things that floe through are changing always. The diameter of the pipeline may have to be changed. But only the extent required. Over size is waste, while undersize would not meet the required throughput.
The BEST flow rate would be that which matches the required output rate.
At times the pipeline itself may have to be modified or even replaced. As changing processes and products introduce whole new set of obstructions.
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In short the work on the pipeline is CONTINUOUS. JIT and TQM continuously enable tinkering the pipeline so that the material coming out of the pipeline is the best possible in all respects.
JIT / TQM Difference in Organizations
JIT /TQM greatly increase the number of people who are involved in identifying and eliminating obstructions. Every one does it Level of authority of workers to make and carry out decisions is much higher Emphasis is on measure, diagnose, and improve it.
Second difference is in the process employed to identify and prioritise problems and sources of waste
In JIT the primary process is reduction of inventory, mainly to reveal the obstructions (which were earlier hidden or ameliorated by the inventory) and prioritise them.
Just in Time Summary
Efficient Techniques Reduce Leeway (Maintaining Continuity)
1. Prepare a disaster plan, e.g. firing protection or backing-up data. He believes that the better the disaster plan, the larger chance the companies will survive after disaster.
2. Cost -reduction strategies.
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3. Develop long-term continuity plan.
4. Identify critical functions and estimate the time, the company can afford without such function.
5. Identify potential alternative suppliers.
6. avoid too complicated continuity plan.
7. Evaluate risk before any decision.
8. Conducting continuity tests.
Just in Time---Manufacturing (1) Introduction
Just in Time---manufacturing is a systems method to develop and operate a factory system. It is mainly basis on the total Decrease of waste. As you know, many people think JIT is not a new knowledge field. As a matter of fact, it has been part and plays an important role of the Japanese manufacturing industry adopted method for a long time. It requires all the materials such as equipment, human resources, and management skills are made available only in the amount required and at the time required to do the job. It is based on producing only the necessary units in the necessary quantities at the necessary time by bringing production rates exactly in line with market demand. Generally speaking, JIT means making what the market wants. JIT has been found to be so effective that it increases
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productivity, work performance and product quality. What‟s even more, it plays a vital role to increase productivity and decrease the total cost of manufacturing production.
(2) Planning for JIT
Since each manufacturing process is different, it is up to the individual company to determine the degree of appropriateness and the final application of JIT. However, it is very important to define the plan and objectives before setting up a JIT manufacturing system. It is impossible to establish a new JIT system that can be used successfully without change.
Therefore, we should take serious consideration to make a plan for Just-In-Time, which will benefit to our factory performance.
(3) Defining the Planning
JIT manufacturing system requires an understanding of the objectives of JIT, and objectives of the JIT system. After the objectives are set up for the manufacturing, the process of planning becomes one of determining what is required to meet those objectives. The goal of a JIT approach is to develop a system that allows a factory to have only the materials equipment and people by hand required doing the some plan. T o achieve this goal, we should have equipped with at least five fundamental plan:
· Integrating and optimizing every step of the manufacturing process · Reducing manufacturing cost · Producing product on demand · Developing
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manufacturing flexibility · Produce quality product to maintain commitments and links made between Customers and Suppliers
We also should keep in mind that achieving these obtaining targets does not automatically make a company a JIT manufacturer. On the contrary, it will lead to achieve even one of these objectives will prevent a manufacturer from establishing a successful JIT system. According to Common Wealth on May, 1996 report, it said that “A company cannot decide to implement JIT;
they must earn the right to use JIT by revising their quality for system."
(4) Reducing Manufacturing Cost
If we can design products that it will speed up and decrease manufacturing processes. Gradually, it will help us to reduce the cost of manufacturing and building the product to specifications benefit. One aspect in designing products for manufacture ability is the need to set up a good boss and employee relationship. At least, this is to cultivate and procure the resources of the production experts, and the line employees to develop cost saving solutions. Participatory quality programs utilize employee knowledge about their job functions and review the department performance. It will, finally, encourage with rewards for suggested total cost saving.
(5) Manufacturing Flexibility
According to China time report on August 1996. "Manufacturing flexibility is the ability to start new projects or the rate at which the production mix can be adjusted to meet customer demand." Planning for manufacturing
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flexibility requires the understanding of the elements in the manufacturing process and understanding elements in the process that restrict flexibility and improving on these areas. The unique feature of Just-In-Time is the modification from between pull and push systems. The main idea behind these approaches is that "work should not be pushed on to the next worker until that worker is ready for it." (Hauser, J.R.) As a result, manufacturing flexibility requires production managers to consider the some important factors, such as supplier lead time, production process time, process setup time and so forth.
(6) Keep in touch between customers and suppliers
For factory main commitment to achieving the internal structures, both customer and supplier are also playing a vital role to support JIT manufacturing. Because it is the primary requirement for developing the JIT system, each other can establish trust and honest between the supplier and the customer which is a must, since every Just-in-Time operation depends on it. Supposed, finally, it leads to failure to keep the commitments each other.
Finally, it will be result to a serious form of breakdown manufacturing systems. Therefore, we should pay attention to this kind of serious call.
Never be ignorant of this commitment. If we can make use of Just-In-Time (manufacturing approaches), it, eventually, will attain those goal, which are the fundamental concept of producing product only as needed or on demand.
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