CHAPTER # 8.

- JIT AND LEAN OPERATIONS

Definition: continuous and forced resolution of problems through a
approach to reduce production time and inventory levels.
The Just in Time method is an industrial philosophy that consists of
to produce only the strictly necessary quantities and in the
precise moment.
TPS (Toyota Production System).- Focus on continuous improvement, the
respect for people and standard work practices.
Lean operations: provide the customer exactly what they want, when
wants it (without waste) through continuous improvement.
JIT emphasizes the forced resolution of problems.
TPS emphasizes learning and the delegation of authority in the
employee in an assembly line environment.
Lean operations emphasize understanding the customer.
Good production systems require that managers
they address 3 general and fundamental aspects for management
of operations:
ELIMINATE WASTE
1.- Overproduction: producing more than what the customer orders or
Producing in advance is waste.
2.- Rows: idle time, storage, and waiting are
waste.
3.-Transport: the movement of materials between plants or centers
work is waste.
4.- Inventory: The unnecessary raw materials, the work in progress, the
Finished products and excess supplies do not add value and are
waste.
5.-Movement: the movement of equipment and people does not add value.
6.- Overprocessing: the work done on the product but
what does not add value is waste.
7.- Defective products: returns, claims of
guarantee, repeated work and leftovers are waste.
5 s: checklists for lean production: separate,
simplify, clean (shine), standardize, and sustain.
1. Separate/simplify: keep what is necessary and remove everything else.
Furthermore, when in doubt, discard it.
2. Simplify/fix: adapt and use analysis tools
methods to improve workflow and reduce waste.
3. Clean/Sweep: clean daily, remove dirt, pollution
and disorder.
4. Standardize: eliminate variations in the process when developing
standardized operating procedures and lists of
verification.
5. Sustain/self-discipline: review periodically to recognize
efforts and motivate the sustainment of progress.
ELIMINATION OF VARIABILITY
Any deviation from the optimal process that delivers a product
perfect on time every time. Causes:
Incomplete or imprecise designs or specifications.
Deficient production processes => practices that do not
meet the standard.
Unknown customer demands.

IMPROVEMENT OF PRODUCTION TIME

Production time: the time required to carry out a
order from reception to delivery.
Manufacturing cycle time: the time that an order is in the
plant, from the time of arrival of the M.P. to the time that it
they embark the PT.
Pull system: it is one that pulls a unit to the point where it
needed, just when required.
JUST IN TIME
The materials are only needed when required.
JIT reduces the costs associated with excessive inventory, reduces the
variability and waste and improve production time.
JIT FACILITIES DISTRIBUTION
The JIT distribution reduces another type of waste: movement.
The JIT distribution places materials directly at the location
where they are needed.
Reduction of distance: working cells are used, arranged in
U-shaped, with several machines performing different operations.
Increase in flexibility: ability to change the arrangement with
ease in adapting them to changes in volume, product improvements
or new designs.
Impact on employees: employees who work together receive
cross-training.
Reduction of spaces or inventory: as well as the JIT distribution
reduce the travel distances, it also decreases the inventory to
remove the space allocated for this.
JIT INVENTORY
Minimum inventory required for a system to function
perfectly. With JIT inventory, the exact volume of goods
arrives at the moment it is needed, not a minute more or a
minute less.
REDUCTION OF VARIABILITY
The idea behind JIT systems is to eliminate the inventory that hides
the variability in the production system.
REDUCTION OF INVENTORY
Reduce inventory to its bare minimum.
REDUCTION OF BATCH SIZE
The key to JIT is to manufacture a good product in small batches.
 The reduction in batch size becomes a great help
to reduce the inventory level and its costs.
JIT PROGRAMMING
Effective programs, communicated both internally to the
organizations as external providers, serve as support
the JIT.
Good programming also improves the ability to
satisfy customer orders, reduces inventory to
allows producing smaller batches and reduces inventory
in process.
Levelled programs: scheduling the products in a way
that the production of each day meets the demand of that day.
They process small and frequent batches instead of just a few.
large lots.
Kamban Card: it is the effort to reduce inventory.
The card is an authorization for the following to occur.
material container.

JIT QUALITY
A JIT system reduces the cost of obtaining good quality
hidden defects in the inventory.
JIT forces a reduction in inventory.
Just as inventory hides poor quality, JIT exposes it.
immediate.
JIT improves quality: JIT reduces waiting lines and time.
of delivery.
Better quality means that less is needed.
shock absorbers.

TOYOTA PRODUCTION SYSTEM

Continuous Improvement: It means building an organizational culture and
instill in their people a system of values that emphasizes the fact that
that the process can be improved and that is an integral part of the work of
any employee.
Respect for people: people are recruited, trained, and are
treated as knowledgeable employees. Authority is delegated to the
employees. They can make improvements.
Standard work practices:
The work is completely specified in terms of contents,
sequences, times and results.
The internal and external connections between the client and the
providers are direct, specifying personnel, methods, time
and quantity.
The flows of products and services must be simple and direct.
Goods and services are directed to a person or machine
specific.
Improvements in systems must be in accordance.
with the scientific method, at the lowest level of the organization.
LEAN OPERATIONS
Lean production starts externally with a focus on the
client.
Understand what the customer wants and ensure that they receive it.
ensuring your feedback is the starting points of the
lean production.
The manager discovers that he creates value for the customer and that
no.
BUILDING A LEAN ORGANIZATION
Companies with lean production share the following
attributes:
They use JIT techniques to eliminate all inventory.
They build systems that help employees produce
a perfect part every time.
They reduce space requirements by minimizing distance.
that travels a part.
They develop close relationships with suppliers,
helping them to extend the needs of the end customer.
They educate the suppliers to accept their responsibility
regarding the satisfaction of the end customer.
They eliminate all activities that do not add value.
They develop employees (training, participation,
commitment, teamwork.
They make jobs more challenging.
They create the flexibility of the worker through training.
crusade and the reduction of the number of job categories.

LEAN OPERATIONS IN SERVICES

The characteristics of lean operations apply to the
services just like in other sectors.
To deliver goods and services to customers under a demand
in constant change, suppliers must be reliable,
lean inventories, short cycle times and programs
agile.
A lean approach involves and delegates authority to the
employees to create and deliver the perception of value of
client, eliminating any element that does not contribute to achieving
this goal.