JIT Assignment 2

Assignment-2.
Nikhil k v
1js14im026.
1. Explain briefly the global implementation of JIT in automobile
industry
The 4 global implementations of JIT in the automobile industry Toyota used
KANBAN system at its motor manufacturing plant in long beach California. This
was the first plant owned and operated by a foreign automaker in US the plant
fabricated, assembled and painted four model of truck bed for Toyota light
trucks through manufacturing functions to a selected number of supplier over a
two Year period. The system used material requirement planning (MRP) for over
all production planning and KANBAN for shop floor control there are many
automobile industry implemented at the first US joint venture between General
motor corporation and Toyota motor corp. called MUMMI to cared at Freemont,
California and produced 200,000 subcompact automobile per year harley Davidson,
the US producer of motor cyde, faced serious problems through the 17 due to high
inventory, srap, rework, production, bottleneck etc in the i8’es the company was
heavy loss of japan competition and implemented JIT as a revitalization strategy.
The JIT programme enabled it to increase its share of heavy weight motorcycles
marked by 50% from a low of 12.5% in 1983 to 19.40% at the end of 1986. The
company called JIT programme 'MAN’ Material as needed.
2 Explain in detail the global implementation of JIT in seasonal demand

industry.
The following application were studied in the seasonal demand industry a
:
1) JIT in a highly seasonal environment
2). The world company
3) Use of Kanban in a job as shop environment.
ATCO, a UK based company, manufactured lawn motors and electric
motors. The former accounted for 80% of its turnover . the lawn mover came
in a wide range of size and option and served mainly 2 markets : domestic
and professional The product was such that little commonly of design and
parts existed across product group. Traditional work practise, machine and
piece work payment system were inherited from its past. ATCO operated in a
highly seasonal demand environment with 60% of annual sale in March-April
and close to no sale in Oct-Nov. The demand was highly uncertain with panic
rather than planned buying being the role. In 1987, ATCO adopted JIT was
prepared as part of its 5 year strategic plan. The JIT application was
selective mainly aimed at high volume, large market share products and
high value parts. The overall strategy called for production smoothing and
application on of JIT to these products.
3. Explain the JIT implementation in process type industry

Application in process type industry. were studied for a variety of manufacturing
situation like food processing, glass blowing plastic processing, printing and chemical
etc. there are many companies under the process type industry
KIBUN Food company, a member of HPSRA Japan, owned over 20 plants in Japan.
It introduced JIT in 1980 at its themes plant which produced perishable goods
including boiled fish paste. JIT philosophy of treating the workers well and
trusting them is what appealed most to Kibon president. JIT was introduced as
a mean to improve its inefficient production and distribution system. Although Kibon
met with early success, JIT soon let to a chaos situation on the shop floor. The
reason was traced to a long existing conflict between the production and sale
arm of the company. Due to the latter being perceived as such stronger. The
situation was corrected with strong management support to the production
operation and MPS was reintroduced. It quickly showed results. The management
put considerable stress on changing the attitude amd promoting co-operation
for the continued growth of the through JIT.
4. Explain JIT implementation survey in US manufacturing firms.

Other manufacturing firms implemented in JIT are:
JIT at Beaver M-C Tools :- This resulted in the introduction of CNC
machine tool range and an increase in the sales turnover from 3.5 million
in 1981 to 11.5 million in 1986- PrioR JIT Beaver faced many problems. Its
cumulative manufacturing lead time was around 36. week, nearly half of which
was due to inaccurate forcast. Typical both quantities were 20.25 equivalent
to 12-16 week stock usage
The implementation was in 4-stage
Education
Piolt
Scheme
Evaluation
Planning
Education: the education in JIT created delivers among work force
Pilot : the pilot application was in the sheet metal area where supervision
was highly motivated
Scheme : a weekly mivkrun scheme was adopted for more frequently
delivers.close relations with the suppliers eliminated incoming inspection and
reduce line stoppage etc
The production engineering department headed a project to reduce the
shop time by 60% in the machine shop over 18 months. This led to the
introduction of innovation like low temp surface hardening process, use
of quick release clamping devices and cranes for fixture handling etc
5. Illustrate the survey analysis of JIT production in UK and west
Germany .
JIT Manufacturing in UK:
Voss and Robinson report a survey of JIT implementation in UK
manufacturing industries they used questionable to obtain data and conducted
interviews in 5 companies known to be adapting JIT
(1) In terms of aspects of JIT planned Flexible workforce (80%), wip
reduction (67.1%) production simplification (60%) preventive maintenance (60%),
statical process control (88.66) setup time reduction (54.3%), 'continuous
improvement (54-3%) JIT purchasing (51.4%), work reams quality control (50%)
, use of std container (44:30%) use of moduler or cels (44.3%) 0 defect (34-
3%), mixed modelling (31.40%), smoothed line build rate (25.7%) parallel lines
(22.8%), U-shaped line (22.9%) and Kanban (11.4%)
2) In terms of ability: zero defect, wip reduction, Kanban, JIT purchasing
U-shaped line, work team quality control modules and cell. This implies that
implementation organization are yet to servive the major benefit from JIT.
3) The rank order for IIT benefits its WIP reduction, increased flexibility,
raw material. reduction, increased quality increased productivity , reduced space
,requirement and lower overheads
JIT survey analysis in west Germany . Wildemann provides an outline of
the JIT approach in west Germany. According to him the intro in Germany is
based on the need to Orient manufacturing towards market requirement. it
requires high utilization of the capital, intense production plant and increased
turnover to the liquid assets. The 82.6 % enterprises that were studied and
to which JIT principles were applied showed an extensive variety of individual
solution.
6 Explain the JIT production in Hong Kong electronics industry

Implementation of JIT posed in the survey were
a) sources from which local manufacturer learn about JIT.
b) How to keep invertory in JIT
c) Most beneficial factor of JIT
d) Impeding factor for successful JIT application.
e) Major reasons for implementing JIT.
1 The majority of manufacturers 65% emphasized carrying minimum
inventory everywhere , low inventory 40% warning on quality problem
and on time shipment 21% were perceived as the most beneficial
factors of IIT.
2 The major impeding factors were supplies inability to deliver on
time 40% and ignorance about JIT 30%
3 High demand the fluctuation (15%) and inadequate process control
techniques (10%) were the other impeding factors.
4 long term cost compete honeness was the main reason (72.5%) for
implementing to Long term quality leadership (20%) and meeting
customer demand (7.80p) were other reasons
8 Explain the following

Interface of JIT with advanced manufacturing technology assessing the
performance in JIT manufacturing systems
JIT is unquestionably one of the most significant developments in manufacturing in

recent times. A parallel development of equal importance is the rapid intro of
several advanced computer controlled Manufacturing technology.
CIM- computer integrated manufacturing CAPP- computer Arded process planning

CAD- Computer Aided Design FMS - Flexible manufacturing system. AS-RS -
Automated storage and Retrieval system AGUS- Automated vehical guidance
system
. for most part, growth in JIT and cim have purged parallel independent path
There es now a growing realization that interfacing of JIT and dim would
dramatically alter the marnufacturing infrastructure bringing its wake strategic
impact of far-reaching consequence withought of before such is already taking
place florough to a bruered enfent resulting en manos facturing system which
have come to be termed on CIJIT- computer Integrated Just in time.
10. explain the quality management system for at Automation and functional
quality Management were the basic building block of the widely known
companywide quality control (CWQC). The Imaon purpose of which was to provide
assurance of the assumed specific Quality Assurance (QA) related
responsibilities in the coal system, for each department
1.product plannings-
i) Fore costing of demand and market share
ii) obtain the quality to satisfy market need. set and assign proper quality
target and cost target. Prevent reoccurrence of important quality problems.
2.Product designs.
i) design of prototype vehicle. meet quality target Test and examine car
for performance safety low pollution, economy, relability:
ii) Initial design to confirm necessary condition.
3. manufacturing preparation.
i) Preparation of overall line to satisfy design quality
ii)Preparation of proper inspection method
iii) Evaluation of initial prototypes
iv) Develop and evaluate a plane of initial and daily process
control
v) Preparation of low capacities
4.Purchasing
i) confirmation of qualitative and quantitative capabilities of each supplier.
ii) Inspect initial parts supplied for product quality.
iii) support is strengthening an system of each suppler.
5. Manufacturing
i) Match product quality to establish standard
ii) Establish property controlled lines
iii)maintain necessary line capacities and m-c capacity.
6 Inspection
i) Inspect. initial product for quality
ii) Decide whether to deliver product for sale.
7. sales and service
i) Prevention of quality decline in packaging, storage and delivery
ii) Education and public relation for proper care and maintenance. .
iii) Inspection of new care.
iv) Feedback and analyses of quality information
11 Explain the overhead allocation in JIT.
The illustrative allocation of overhead on the basis of the amount of
time a part spend in the plant in JIT environment companies may have
significant fixed cost which are the result of the parts spending too much
time in the plant including the cost carrying to inventories as well as much
to me in the plant, as well as cost of warehouses, store rooms, Ispace on
the shop floor material handling personnel and so on. Equitably allocation
of these cost would encourage the organisation, to reduce the time a part
spend in the plant because this would result in cost reduction.

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Assignment-2.

2 Explain in detail the global implementation of JIT in seasonal demand

3. Explain the JIT implementation in process type industry

4. Explain JIT implementation survey in US manufacturing firms.

6 Explain the JIT production in Hong Kong electronics industry

8 Explain the following

JIT is unquestionably one of the most significant developments in manufacturing in

CIM- computer integrated manufacturing CAPP- computer Arded process planning

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