JIT – Just In Time

• An important lean tool

• A way of thinking, working and managing to eliminate waste in a process

• Elimination of anything that does not add value

• Production of the minimum, using the minimum at the latest possible time

• JIT is a company wide improvement activity involving ALL

staff and ALL departments

• JIT is one of three key NPW tools, with an annually reviewed

productivity saving target

• JIT principles have been applied in the indirect areas

(Indirect Dept Improvement Activity)

• JIT is used to critically challenge conventional attitudes by

examining material flow to identify waste

JIT – Within NMUK

• Operators

• Time (centiminutes)

• Area (square metres)

• Distance (metres)

• Stock

• Process flow steps

JIT – Standard Measures

Operation

Transport

Store

Inspection

Delay

JIT – Standard Process Flow Symbols

Operation

The material part or product is modified or changed

JIT – Standard Process Flow Symbols

Transport

Movement of parts or materials fromplace to place

JIT – Standard Process Flow Symbols

Store

A waiting period between events where the location is controlled

JIT – Standard Process Flow Symbols

Inspection

Checking for quality or quantity

JIT – Standard Process Flow Symbols

Delay

A waiting period between events wherethe location is not controlled

JIT – Standard Process Flow Symbols

JAM STORED

IN FRIDGE

INSPECTION

TRANSPORT

OPERATION

TRANSPORT

DELAY

STORE

IS IT OK ?

TAKE TO

BREAKFAST

TABLE

WAITING

FOR

TOAST

SPREAD ON

TOAST

RETURN TO

FRIDGE

STOREJAM STORED

IN FRIDGE

JIT – Flow Process Example

• Remove all stock ! (Heart attack method)

• Incremental reduction (Planned, in stages)

• Quarantine reduction (Use of ‘safety’ stock)

JIT – Stock Reduction Approaches

Conventional Attitude

• Large lots are more efficient

• Faster production is efficient

• Scheduling and queues are

necessary trade offs to maximise

machine and manpower output

• Inventory provides safety

• Inventory smooths production

JIT Attitude

• Ideal lot size is one piece

• Balanced production is ideal

• Trade offs prevent the correct

approach, of eliminating the

concern

• Safety stock is waste

• Inventory is the root to all

evil

JIT – Stock Reduction Approaches

• Three stage approach

• Pre work prior to activity

• Select Area and set scope

• Produce a video and process flow

• Two day activity

• Follow up activity

• Implement any long term actions

• Buy off full activity

JIT – Two day activity overview

• Kick off meeting

• Walk the process & initial analysis

• Generate ideas

• Identify attainable

• Confirm feasibility and countermeasures

• Simulate attainable condition (try out)

• Review solutions and outcomes

• Summarise outcomes and action plan

JIT – Two day activity

Now Condition

Current condition

Ideal Condition

Best PossibleCondition

JIT drives towards the ideal condition

Attainable Condition

Best practicalcondition that can

be achieved

JIT – Ideal Condition

• Optimum Solution

•What is both practical and possible taking into

consideration all constraints.

•This is the nearest solution to the ideal that can be

achieved

•MUST be a real improvement and MUST produce real

savings

JIT – Attainable Condition

List all the

steps here

JIT – Analysis Sheet

JIT – Complete the Process flow

• Evaluate Each line

item asking:

• Why each element

has to be done ?

• How can it be

done better?

• How can it be

done easier?

• (five why’s &

SWOT)

JIT – Complete the waste analysis

JIT - Analysis

JIT - Analysis

• Over production

• Idle time

• Transportation

• Non Value added processes

• Stock

• Unnecessary motion

• Inferior quality

Seven Wastes

• Making too much or too soon

• Making more than is required by the customer

• Making products which may not be used

Seven Wastes – Over Production

• Waiting for parts / stock, other operations

• Operators working ahead (unbalanced

workload)

Seven Wastes – Idle Time

• Moving parts from one location to another

Seven Wastes - Transportation

Seven Wastes – Non Value added processes• Processes that do not change the product

(masking, counting, inspection, sequencing etc)

Seven Wastes - Stock

• Stock hides other wastes

• Stock costs money to

make, manage and

maintain

Seven Wastes – Unnecessary Motion

• Shorten motion distances

• Combine motion

• Reduce the number of motions

• Make motions easier

Seven Wastes – Inferior Quality

• Failure to perform to specification

• You can’t inspect in quality

• Inspection adds cost not quality