Chapter 12 The just-in-time system

Publisher Summary This chapter presents an overview of Just-in-Time (JIT). There are two keys to JIT supplier logistics: taking control of inbound deliveries and establishing quick feed-back loops. Various models have been proposed to investigate the improvement and learning processes the JIT system seeks to foster. To maximize the probability of success of a JIT program, it is also necessary to put proper incentive systems in place that encourage employees and management to implement the desired changes, and to redefine areas of responsibility throughout the organization. The purchasing firm also attempts to level its production schedule to make JIT deliveries possible without significant buffer inventories. The extension of JIT across firms thus creates mutual dependencies between supplier and customer, and hence incentives to cooperate to resolve problems and increase efficiency. Geographical distance between supplier and customers limits the potential for achieving JIT deliveries. A customized JIT program will have to be designed to fit the particular circumstances of an organization, and a cost/benefit analysis may indicate that JIT is not appropriate.

[1]  J. A. Buzacott,et al.  Queueing models of Kanban and MRP controlled production systems , 1989 .

[2]  Peter O'Grady,et al.  Kanban controlled pull systems: an analytic approach , 1989 .

[3]  Byron J. Finch.  Japanese management techniques in small manufacturing companies: A strategy for implementation , 1986 .

[4]  Douglas K. Macbeth,et al.  Lessons in buyer-vendor relationships with JIT , 1988 .

[5]  Uday S. Karmarkar.  Push, Pull and Hybrid Control Schemes , 1991 .

[6]  Maling Ebrahimpour,et al.  Dynamic Simulation of a Kanban Production Inventory System , 1985 .

[7]  James F. Cox,et al.  An examination of just-in-time management for the small manufacturer: with an illustration , 1986 .

[8]  T. Tabe,et al.  Analysis of production ordering quantities and inventory variations in a multi-stage production ordering system , 1980 .

[9]  J Black.  CELLULAR MANUFACTURING SYSTEMS REDUCE SETUP TIME MAKE SMALL LOT PRODUCTION ECONOMICAL , 1990 .

[10]  Debasis Mitra,et al.  Analysis of a Kanban discipline for cell coordination in production lines , 1990 .

[11]  Nallan C. Suresh,et al.  Achieving factory automation through Group Technology principles , 1985 .

[12]  James F. Cox,et al.  A study of JIT implementation and operating problems , 1988 .

[13]  Panganamala Ramana Kumar,et al.  Optimality of Zero-Inventory Policies for Unreliable Manufacturing Systems , 1988, Oper. Res..

[14]  G E Whitehouse,et al.  A Program For Pert On A Minicomputer , 1981 .

[15]  Willard I. Zangwill,et al.  Eliminating inventory in a series facility production system , 1987 .

[16]  Richard J. Schonberger,et al.  “Just‐In‐Time” Purchasing Can Improve Quality , 1984 .

[17]  Shigeo Shingo.  A Revolution in Manufacturing: The SMED System , 1985 .

[18]  John Miltenburg,et al.  Scheduling mixed-model multi-level just-in-time production systems , 1989 .

[19]  G. Stalk.  Time-The Next Source of Competitive Advantage , 1988 .

[20]  Arnoldo C. Hax,et al.  Production and inventory management , 1983 .

[21]  R. Anthony Inman,et al.  The Transferability of Just-in-Time Concepts to American Small Businesses , 1990 .

[22]  Loren Paul Rees,et al.  Dynamically Adjusting the Number of Kanbans in a Just-in-Time Production System Using Estimated Values of Leadtime , 1987 .

[23]  Larry C. Giunipero,et al.  Obstacles to JIT procurement , 1988 .

[24]  Charles H. Fine,et al.  Managing quality improvement , 1984 .

[25]  Ashok Rao,et al.  JIT with MRP II creates hybrid environment , 1988 .

[26]  大野 耐一,et al.  Just-in-time for today and tomorrow , 1988 .

[27]  Larry C. Giunipero,et al.  JIT Purchasing in a Non‐Manufacturing Environment: A Case Study , 1987 .

[28]  R. Schonberger,et al.  Reinventing Inventory Control , 1984 .

[29]  Joseph A. Bockerstette.  Misconceptions about the JIT operating philosophy , 1988 .

[30]  Uday S. Karmarkar,et al.  Batching Policy in Kanban Systems , 1989 .

[31]  Osamu Kimura,et al.  Desiǵn and analysis of Pull System, a method of multi-staǵe production control , 1981 .

[32]  Loren Paul Rees,et al.  An investigation of the factors influencing the number of Kanbans required in the implementation of the JIT technique with Kanbans , 1987 .

[33]  K.H.W. Seah,et al.  JIT and the Effects of Varying Process and Set‐Up Times , 1988 .

[34]  Y. Monden.  Toyota Production System: Practical Approach to Production Management , 1983 .

[35]  S. Jordan.  Analysis and Approximation of a JIT Production Line , 1988 .

[36]  Richard J. Schonberger,et al.  Building a chain of customers : linking business functions to create the world class company , 1991 .

[37]  Charles H. Fine.  A Quality Control Model with Learning Effects , 1988, Oper. Res..

[38]  L. C. LEEj.  Parametric appraisal of the JIT system , 1987 .

[39]  Yasuhiro Monden,et al.  “A SIMULATION ANALYSIS OF THE JAPANESE JUST‐IN‐TIME TECHNIQUE (WITH KANBANS) FOR A MULTILINE, MULTISTAGE PRODUCTION SYSTEM”: A COMMENT* , 1984 .

[40]  Uday S. Karmarkar,et al.  Alternatives for Batch Manufacturing Control , 1986 .

[41]  John McMouse.  Some lessons from a decade of Group Technology , 1980 .

[42]  Amrik S. Sohal,et al.  A Review of Literature Relating to JIT , 1989 .

[43]  Mehran Sepehri.  Manufacturing revitalization at Harley-Davidson Motor Co. , 1987 .

[44]  Gabriel R. Bitran,et al.  A mathematical programming approach to a deterministic Kanban system , 1987 .

[45]  Clive H. Elphick,et al.  Operations Research Techniques for Management , 1979 .

[46]  H Ohta,et al.  The optimal operation planning of Kanban to minimize the total operation cost , 1988 .

[47]  Charles S. Tapiero,et al.  Production Learning and Quality Control , 1987 .

[48]  Y. Sugimori,et al.  Toyota production system and Kanban system Materialization of just-in-time and respect-for-human system , 1977 .

[49]  Ronald G. Conant.  How using JIT in a mail order operation reduced processing time , 1988 .

[50]  Charles H. Fine,et al.  Dynamic Process Improvement , 1989, Oper. Res..

[51]  C. Das,et al.  A Vendor′s View of the JIT Manufacturing System , 1989 .

[52]  Evan L. Porteus.  Investing in Reduced Setups in the EOQ Model , 1985 .

[53]  Helmut A. Welke,et al.  Using cellar manufacturing to implement just-in-time and total quality control , 1988 .

[54]  Charles H. Fine.  Quality Improvement and Learning in Productive Systems , 1986 .

[55]  S. Sethi,et al.  A Note on "Level Schedules for Mixed-Model Assembly Lines in Just-in-Time Production Systems" , 1991 .

[56]  R. Schonberger.  Japanese manufacturing techniques : nine hidden lessons simplicity , 1982 .

[57]  Uday S. Karmarkar,et al.  Lot Sizes, Lead Times and In-Process Inventories , 1987 .

[58]  Edward J. Hay.  Any machine set-up time can be reduced by 75% , 1987 .

[59]  Paul H. Zipkin,et al.  Models for Design and Control of Stochastic, Multi-Item Batch Production Systems , 1986, Oper. Res..

[60]  Kazuyoshi Ishii,et al.  Some ways to increase flexibility in manufacturing systems , 1985 .

[61]  H. Ford,et al.  My Life and Work , 1922 .

[62]  Taiichi Ohno,et al.  Toyota Production System : Beyond Large-Scale Production , 1988 .

[63]  Lee J. Krajewski,et al.  Kanban, MRP, and Shaping the Manufacturing Environment , 1987 .

[64]  Inyong Ham,et al.  Group Technology - An Overview and Bibliography. , 1976 .

[65]  Stanley B. Gershwin,et al.  Modeling and Analysis of Three-Stage Transfer Lines with Unreliable Machines and Finite Buffers , 1983, Oper. Res..

[66]  Debasis Mitra,et al.  Analysis of a Kanban Discipline for Cell Coordination in Production Lines, II: Stochastic Demands , 1991, Oper. Res..

[67]  Jeff Barrett,et al.  Implementing world class manufacturing—a case study , 1988 .

[68]  R. A. Dudek,et al.  A categorized survey of the JIT literature , 1991 .

[69]  Thomas P. Ryan,et al.  Statistical methods for quality improvement , 1989 .

[70]  Evan L. Porteus.  Optimal Lot Sizing, Process Quality Improvement and Setup Cost Reduction , 1986, Oper. Res..

[71]  W. Edwards Deming,et al.  Out of the Crisis , 1982 .

[72]  William L. Maxwell,et al.  The Role of Work-in-Process Inventory in Serial Production Lines , 1988, Oper. Res..

[73]  R. R. Inman,et al.  Sequencing JIT mixed-model assembly lines , 1991 .

[74]  Loren Paul Rees,et al.  A SIMULATION ANALYSIS OF THE JAPANESE JUST‐IN‐TIME TECHNIQUE (WITH KANBANS) FOR A MULTILINE, MULTISTAGE PRODUCTION SYSTEM , 1983 .

[75]  W. Zangwill.  From EOQ Towards ZI , 1987 .

[76]  W. Deming.  Quality, productivity, and competitive position , 1982 .

[77]  David L. Woodruff,et al.  CONWIP: a pull alternative to kanban , 1990 .

[78]  Evan L. Porteus.  Investing in new parameter values in the discounted EOQ model , 1986 .

[79]  U. Karmarkar,et al.  Lotsizing in Multi-Item Multi- Machine Job Shops , 1985 .

[80]  Awi Federgruen,et al.  A Combined Vehicle Routing and Inventory Allocation Problem , 1984, Oper. Res..

[81]  Charles S. Snead.  Group technology : foundation for competitive manufacturing , 1989 .

[82]  Y A Hosni,et al.  Line Of Balance (Lob) Using A Microcomputer , 1981 .

[83]  A Etzioni,et al.  Humble decision making. , 1989, Harvard business review.

[84]  Kelvin F. Cross,et al.  Workflow analysis, just-in-time techniques simplify adminstrative process in paper work operation , 1988 .

[85]  Joseph Moses Juran.  Juran on planning for quality , 1988 .

[86]  Abraham Seidmann,et al.  Regenerative pull (Kanban) production control policies , 1988 .

[87]  T. Ohno.  How the Toyota Production System was Created , 1982 .

[88]  Wanda Savage-Moore.  Creating a JIT environment at a customer service center , 1988 .

[89]  Richard J. Schonberger,et al.  Just-in-Time Purchasing: A Challenge for U.S. Industry , 1983 .

[90]  新郷 重夫,et al.  A study of the Toyota production system from an industrial engineering viewpoint , 1989 .

[91]  J. Miltenberg,et al.  Level schedules for mixed-model assembly lines in just-in-time production systems , 1989 .

[92]  U. Karmarkar.  Getting control of just-in-time. , 1989, Harvard business review.

[93]  Richard J. Schonberger.  Applications of Single-Card and Dual-Card Kanban , 1983 .