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Chapter 15
JIT and Lean Operations

Roboam Kakap
2 Learning Objectives
1. Explain what is meant by the term lean operations systems

2. List each of the goals of JIT and explain its importance

3. List and briefly describe the building blocks of JIT

4. List the benefits of the JIT system

5. Outline the considerations important in converting a traditional mode of

operations to a JIT system

6. List some of the obstacles that might be encountered when converting to a JIT

system

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3 Just-in-time (JIT)
A highly coordinated processing system in which goods move through

the system and services are performed just as they are needed

Lean operations

a highly coordinated system that uses minimum resources and produces

high quality goods or services

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4 Overview of the goals and building blocks of lean
systems
Ultimate Goal
A balanced rapid flow
Supporting Goals
1. Eliminate disruptions
2. Make the system flexible
3. Eliminate waste
Building Blocks
4. Product design
5. Process design
6. Personnel/organisational elements
7. Manufacturing planning and control

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5 Ultimate Goal of JIT

Balance system

Smooth flow and rapid flow of materials/work through the system

Idea to make the process time as short as possible by using resources in the

best possible way.

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6 Supporting Goals
1. Eliminate disruptions

2. Make the system flexible

3. Eliminate waste, especially inventory

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7 Building Blocks
1. Product design

2. Process design

3. Personnel/organisational elements

4. Manufacturing planning and control

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8 1. Product Design
Four elements of product design in JIT

1. Standard parts

2. Modular design

3. Highly capable production systems with quality built in

4. Concurrent engineering

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9 Process Design
1. Small lot sizes

2. Setup time reduction

3. Manufacturing cells

4. Quality improvement

5. Production flexibility

6. A balanced system

7. Little inventory storage

8. Fail-safe methods

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10 Personal/Organisation Elements
1. Workers as assets

2. Cross trained workers

3. Continuous improvement

4. Cost accounting

5. Leadership/project management

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11 Manufacturing Planning and Control
1. Level loading

2. Pull system

3. Visual systems

4. Limited work-in-process (WIP)

5. Close vendor relationships

6. Reduced transaction processing

7. Preventive maintenance and housekeeping

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12 Transitioning to a JIT system

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13 Planning a successful conversion
Top management commitment

Study the operation carefully and decide which parts to convert

Begin by reducing setup time while maintaining the current system

Gradually convert operations, beginning at the end of the process and working

backwards

As part of the last steps, convert supplier to JIT and be prepared to work closely

with them

Be prepared to encounter obstacles to conversion

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14 Obstacles to conversion
1. Management may not be totally committed and unwilling to commit the

necessary resources

2. Workers and/or management may not display cooperative spirit as of

the great responsibility and stress

3. Difficult to change the culture

4. Suppliers may resist for several reasons

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15 JIT Services

Roboam Kakap