Just-In-Time Manufacturing

by Cheng, T. C. E.; Podolsky, S.

• ISBN13: 9780412456909
• ISBN10: 0412456907
• Format: Hardcover
• Copyright: 1993-02-01
• Publisher: Chapman & Hall

Summary

This book addresses three fundamental building blocks of JIT, namely setting up a JIT production system, improving quality, and instilling total employee involvement. JIT implementation issues are covered and supported by an industrial case study.

Table of Contents

Preface
Introduction	p. 1
History and development of JIT manufacturing	p. 2
Elements of a JIT manufacturing	p. 4
People involvement	p. 5
Plants	p. 6
Systems	p. 7
The goals of JIT	p. 7
Advantages and limitations of JIT	p. 10
Advantages of JIT	p. 10
Limitations of JIT	p. 11
The rationale for implementing JIT	p. 12
Prerequisites to a JIT program	p. 17
Plant evaluation	p. 17
Management influence	p. 18
Housekeeping activities	p. 18
Organizational flexibility	p. 19
Layout of the rest of the book	p. 19
Just-in-time production	p. 20
Workplace organization	p. 21
Clearing and simplifying	p. 21
Locating	p. 23
Cleaning	p. 23
Discipline	p. 23
Participation	p. 24
Visibility	p. 25
Preventive maintenance	p. 28
JIT production planning	p. 39
Customer orientation	p. 41
Plant arrangement for JIT production	p. 46
Linking demand pull with cellular manufacturing	p. 59
Automation	p. 70
Flexible plant	p. 71
Focused factors	p. 77
JIT production control	p. 82
The kanban system	p. 83
Rules for kanban operation	p. 84
Preparing the plant for the kanban system	p. 85
Lead time and cycle time reduction	p. 89
Implementing the kanban system	p. 91
JIT and MRP	p. 92
Just-in-time logistics	p. 99
JIT purchasing	p. 99
Contrasts between JIT and traditional purchasing	p. 99
Supplier selection	p. 103
Supplier education	p. 109
Supplier commitment and customer dependency	p. 109
JIT delivery	p. 115
Increasing delivery frequency through production related elements	p. 116
Improving customer delivery through problem identification and resolution	p. 118
Improving customer delivery through forecasting and DRP	p. 120
Total quality management	p. 123
Quality and quality costs	p. 124
Quality: a systems perspective	p. 125
The cost of quality	p. 129
A general guideline to quality improvement	p. 129
Defining employee roles in the quality improvement process	p. 131
Quality improvement through employee ownership	p. 133
Quality of design	p. 136
Defining quality of design	p. 136
Improving the quality of design	p. 137
Quality of conformance	p. 140
Quality of services	p. 146
Quality issues in JIT	p. 152
Increasing customer responsiveness	p. 152
Continuous improvement	p. 152
Total employee involvement: the key to JIT success	p. 153
Total quality control	p. 154
Quality circles	p. 156
Managing in-process quality	p. 160
Brainstorming and NGT	p. 160
The 5 'whys'	p. 161
Pareto charts	p. 161
Histograms	p. 163
Check sheets	p. 163
Flip charts	p. 164
Analysis of cause and effect	p. 164
Total employee involvement	p. 168
Teamwork	p. 168
Management commitment to teamwork	p. 171
Employee education and training	p. 173
Factors of successful training and education programs	p. 173
Incentives for employees	p. 175
JIT discipline	p. 178
Employee work ethic	p. 178
JIT and employee motivation	p. 180
JIT work procedures	p. 181
JIT vs. traditional work practices	p. 181
JIT standards and measurements	p. 183
Implementing JIT manufacturing	p. 184
Developing an implementation strategy	p. 184
An operational plan for implementation	p. 185
Data collection and measurement systems	p. 187
Pilot projects	p. 189
Dealing with employee resistance and unions	p. 190
Industrial case study	p. 194
Introduction	p. 194
TQM project	p. 195
Development of the TQM project	p. 195
The repair and overhaul process	p. 196
Implementation of TQM	p. 197
Measuring and monitoring progress	p. 202
Preparing employees for TQM	p. 204
TQM production issues	p. 205
Quality issues	p. 208
Teamwork building issues	p. 211
Learning experience with TQM	p. 212
References	p. 217
Index	p. 222
Table of Contents provided by Blackwell. All Rights Reserved.