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The purpose of starting the just in time concept was to see to it that nothing is
stocked but is ordered and brought in during the time of assembly and to reduce
inventory cost.
Basic elements of JIT
Flow/Plant layout – The physical layout of production facilities is arranged so that
the process flow is as streamlined as possible i:e for each component, the
proportion of value adding time is maximized and the proportion of queuing and
non-value-adding time is minimized. The flow is analyzed in these terms and the
layout configured accordingly, resulting in the reduction and/or elimination of stores
and conveyers. Use of dedicated line, V-shaped or parallel line, use of small
machine with multiple copies, small plants with multiple copies may be possible.
Flexibility of equipment is essential to adjust quickly to change in market demand,
type etc.
Organization in modules or Cells
Many JIT factories are organized in small autonomous modules or cell, each cell
totally responsible for its own production and supply of the adjacent module, The
cells are designed so that the material flow between cells is minimized. For this
purpose it is common to create “Families“ of parts which are then processed by a
dedicated “Group“ of machines in a cell. Within the cell the work force is trained to
work as a group and often many functions normally considered as staff functions
such as scheduling and maintenance are brought into the cell or module.

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1. Set-up-reduction – The object of minimizing setup time is to reduce the batch size
to the minimum possible, thus reducing the manufacturing cycle time and
inventory. This also results in release of floor space and minimizing material
handling. Use of “SMED“ – Single minute exchange of die system – is common to
set up reduction projects.
2. Small batch size – The batch size can be reduced even to ‘one‘. This possible
because the set up time is reduced and explained in above paragraph. This helps
in producing the exact quantities required and can also meet the variety of
demand. The same principle is applied to supplier who matches to the demand of
the plant. This principle avoids buildup of inventories in “Work in Process“. This
also results in smooth flow and reduction of shop lead time.
3. Demand pull system – In the widely used "push" method, planned production
quantity is determined by demand predictions and inventory on hand, succeeding
production periods are determined from standard time of each set up; the product
is then produced in sequence starting from process one. In the “pull“ method of
JIT system, the final process withdraws the required quantities from the
preceding process at a certain time and this procedure is repeated in reverse
order up through all the earlier processes, the Toyota production system is the
"pull“ method.
4. Quality products design – The achievement of high quality levels is a prerequisite
of successful JIT. Commonly used quality program, in support of JIT include Zero
defect statistical process control (SPC) process data collection, workers centered
quality control, autonomous inspection and counting.
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4. Product and process simplification is achieved by two measures the nationalization
of the product range and the simplification of the methods of manufacture.
Simplification is also brought about through components item standardization and
components routing standardization. These are achieved at the stage of product
design itself.
5. JIT comparison with MRP II – MRP II is a computer integrated manufacturing
system commonly used in the west. While JIT is a manually tabulated system
followed in Japan and the comparison are tabulated below.
Sr. Functions MRP II JIT
No.
1 Planning materials capacity Computer Integrated Manually done with few
and dispatching
2 Shop floor control Planned to read computer Heavily depends on foremen
outputs and operations
3 Materials requirements Advises replenishments well Withdrawal based replenishes
in advance (warehouse materials that are depleted
required)
4 Resource planning Has excellent system to plan Kanban control cards is used.
all resources including Multi skills and flexibility help
distribution in planning
5 System integration Fully integrated with the Control only through Kanban
systems of the company cards. No integration of
systems
6 Application For mass production and high For customized, small
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6. Total productive maintenance (TPM) – In the medical world, sickness of patient was
joint responsibility of the doctor as well as the patient, so also in due manufacturing
world, maintenance must be joint responsibility of the production operator and the
maintenance engineer. Everyone form top executive down to the operator is to be
concerned with the reliability of the equipment. The operator has a special role in
TPM. He must eliminate minor defects in the equipment's before the major
breakdown happens. The production market should not pursue short term gain in
production at the cost of life of the equipment's. He should release due machines for
preventive maintenance as per schedule. Workers active participation in required in
TPM.

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Benefits of JIT
1. Product cost – Greatly reduced due to reduction of manufacturing cycle time.
Reduction of scrap (recycling), inventories, spares requirements, elimination
of non value adding operations.
2. Quality – is greatly improved due to fast detection and correction, use of
automatic stop devices (motion sensor and sound sensor) technologies,
workers centered quality control, SPC etc.
3. Design – Fast response to engineering change, alternative designs (LED to
OLED to QLED – Flexible screens – see video) etc.
4. Productivity & flexibility – Productive improvements using flexible workforce,
reduced rework, reduced inspection, response to changes in demand etc.
5. Administrative efficiency – there are fewer suppliers, minimum expenditure,
simple communication and receiving. Oncoming inspection eliminated through
self certification . Vendors closer to the plants to receive components JIT
directly to assembling areas. Operation is cost effective and products are
competitive.

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