JITP

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KAIZEN in Just-In-Time
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Production System
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Hasan Haider, NPO Pakistan 1

The challenges for our Industry
We need
We need to
to be
be able
able to
to do
do three
three things
things well,
well, all
all at
at the
the same
same time!
time!
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Reduce Cost al Reduce Lead Time Improve Quality
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Production Costs
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Customer Price
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Net Margin
“Cheaper” “Faster” “Better”

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KAIZEN in Just-In-Time
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Production System
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Jay-eye-tea
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JIT
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 Toyota Production System

1
“What issue/concept will be most
important to you in the 1990’s ?”
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Reduction of Production Lead Time
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Source: Sanno College “Seisan-shi Textbook” 1
Meeting the Challenge
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 Requires a new way of thinking.
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 Training in new methods.
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
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Leadership and commitment at all levels.
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 Implementation - do it.
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 Need to do more than talk.

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
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We learn by doing.
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 Improvements don’t have to be expensive.

JIT - A set of tools that fit together
g ci n
la e
Work
Ta k t
Ba Lin
t omer
n
Cus Multi-
lier Cells
Supp ships
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ion
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Relat Time
rs
Process
ve
y
Qualit
al ation Lev s s u ran ce
Ma
Auton om el
5S A
tri
int
en Dem
an
ne
ce and
On
hi
Attack
Pie e
ac
c On
Flo e
ty
Spiri
fM
w Waste
fe
t
Sa
m all
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Visual S
Lot
Size
Controls up t ake
st em S et Sta
nda Mis
ll Sy rd
Pu c tion Wo f ing
u o
Red rk Pro
JIT - A Strategy Based on Lead Time
Adding Value
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Opportunity al
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Lead Time
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A strategic focus to economically make

drastic reductions in lead times to better serve
the customer.

JIT - A Toolset For Eliminating Waste
JIT Tools used
n
to identify and
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eliminate
rs
$ $
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waste from the $ $ $ $
process. al $ $ $
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Same Value-Add
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Result: Shorter Reduced lead time

lead times,
reduced costs. Reduced costs

The Spirit of Improvement
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 Improvement is everyone's job.
rs

ve
Think of ways to make ideas work.
 Don’t say “can’t.”
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 50% improvement is OK.
ne
 Don’t substitute money for brains.

hi
 Ask “Why?”, five times.

ac

fM
Improvement is not made from a conference

pd
room.
 More ideas are better, especially from people
close to the problem.
 Follow up to make sure the idea is working.
 Improvement is endless.
Purpose of a Kanban System
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1) Control of inventory movement.
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2) Authorize production.
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3) Regulate amount of inventory in the

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system.
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4) Provide a visual control that makes

pd
overproduction obvious.
5) A tool for driving continuous
improvement.
Rules for Kanban Systems
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1) Pull from the downstream process (or customer)
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drives the system.
al
2) All product or inventory is under kanban control.
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3) Only an “empty” kanban authorizes production.
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4) Never pass a known defect downstream.

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5) Use gradual kanban reductions to drive improvement.

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Kanban
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Is a “signal” that:
rs
The signal can be a:
ve
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• Authorizes production • Card
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• Authorizes movement • Square
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• Limits inventory • Box

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• Pigeon hole
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• Light
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• Etc.

How Many Kanbans?
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(True Lead Time + Safety Time) = Total Time
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Total Time x Production Requirement = Units in Pipeline

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Units in Pipeline
= Number of Kanbans
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Units per Kanban

Pull Production System
Definition
n
• A customer driven system that produces and
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moves a product/service only when the
ve
customer needs it
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Kanban Work Kanban Work Kanban

1 Center A 2 Center B 3
Work Flow
Push System
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Pull System
Push and Pull System 2
Supermarket Concept & KANBAN
System
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KANBAN
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pd

1
Just-In-Time (JIT) system
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The concept of producing or conveying
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only those units needed,
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just when they are needed,

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in just the amount needed,

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at all stages of production.

By Toyota Motor Company
1
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 ve
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Mistake Proofing Overview
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
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Poka-Yoke
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Mistake-proof (Poka-yoke)
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Note: “Poka” ----- Carelessness; Absent-mind
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“Yoke”----- Elimination
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
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This refers to the thoughtful use of

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devices which eliminates operator’s

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careless mistakes.

Mistake-Proofing
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
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Purpose
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 The mistake-proofing process
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prevents mistakes before they

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create defects.
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pd

What is Poka-Yoke Mistake-Proofing ?
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 An Organized Approach to a “Common Sense”
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Way of Eliminating Defects
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 Mistake Proofing Is a Philosophy That:
ne

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Recognizes People Forget and Make Errors

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 Uses Common Sense (Mistake Proofing) Ideas

fM
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and Methods in Product and Process Design to

Eliminate Human and Mechanical Errors

Mistake-Proofing

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Why do mistake-proofing?
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 Improve quality
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 al
Eliminate rework
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 Reduce cost
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
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Improve schedule performance (especially

ac
in relation to the predictability of cycle

fM
times
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 “Zero” Quality Control (Zero Defects)

 Total Customer Satisfaction
 Quality, Cost, Delivery, Safety, Morale
Benefits and Results
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Benefits Results
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
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 Makes it easy to do the Improves quality
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right things in the right  Reduces costs
al
order in the right way.
 Improves on-time delivery
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 Prevents accidentally

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doing the wrong things Reduces or

eliminates accidents
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in the wrong order in the

ac
wrong way  Improves morale

fM
pd

Mistake-Proofing in Everyday Life
n
 Car safety belt warning light or buzzer.
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 Clothes iron that shuts itself off if left on inadvertently.
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 Garage door opener with safety reversing switch.
al

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A car that cannot be started in gear.
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 Microwave ovens that will not start with the door open
hi
 Beeper to Indicate the Lights Are Left on When the Keys Are
ac
Removed From the Ignition Switch

fM
 Cruise Control Which Shuts off When the Brakes Are Applied
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 Turn Signal Warning Beep When Left on

Examples of Common Devices
n

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Safety Features in the Products
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Carrier Produces:
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 al
Gas Furnace With an Interlock Switch
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That Shuts Down the Furnace When
ne
Panels Are Removed

hi

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Thermostat Which Prevents “Heat”

fM
and “Cool” From Being Turned on at

pd
the Same Time

Examples of Common Devices
 In Manufacturing:
n
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– Safety Devices on Presses
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• Palm Buttons
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• Light Curtains
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• Brake Monitors
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– Fire Drills, Safe Exit Plans

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– Pressure Switches, Monitors

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– Panic Door Hardware on All Exterior Doors

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– Fixtures Which Prevent Parts From Being

pd
Incorrectly Positioned
– Tools Which Reach a Specified Torque then
Shut off

Why Do Mistake Proofing ?
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Customers Demand 100% Defect Free Products
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
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100% Inspection Won’t Provide 100% Defect Free
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Products

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Cost Pressures Don’t Allow for Continued Mistakes
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– Scrap
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– Rework
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– Missed Schedules
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 Lean Manufacturing Will Not Tolerate Mistakes

– One Piece Flow Demands Good Quality Parts
All the Time
– Batch Processing Can Hide Mistakes With
Excess Inventory Hasan Haider, NPO Pakistan 27
100% Inspection Exercise
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Please Find and Count All the F’s
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in This Letter
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John Foster 3-21-92

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Quality Engineer Date

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Finished Files Are The Result Of

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Years Of Scientific Study Combined

With The Experience Of Years

7 F’s Total - How Many Did You Each Find ?
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Please Find and Count All the F’s
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in This Letter
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John Foster 3-21-92

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Quality Engineer Date

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Finished Files Are The Result Of

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Years Of Scientific Study Combined

With The Experience Of Years

Is 99.9% Quality Good Enough for You ?
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If It Is, Then You Won’t Mind 0.1%
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Defectives: I’ll do better
next time!
 al
Doctors in New York State Hospitals Drop
tri
288 Babies Per Year
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
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Post Offices in New York State Lose 61,626

ac
Pieces of Mail Per Day

fM
pd
 Chicago O’Hare International Airport Has

1,264 Unsafe Arrivals / Departures Per Year

Examples of Errors Vs. Defects
n
Error - (Cause) Defect - (Effect)
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Leave the Iron on Then
Leave for Work
rs
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al
Pump Diesel Fuel Into Your
tri
Gas Tank
ne
?
hi
Run a Red Light

ac
fM
Not Setting the Timer

pd
Properly on Your Toaster
Placing the “Original” in Your

Copier “Face up.”
Running Out of Ink on Your

Date Coder
7 Step Mistake Proofing Process
n
1. Describe the Defect in Detail.
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2. Identify Process or Operation Where Defect Can First Be
rs
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Discovered - Where Defect has Actually Been Created.
al
3. Map the Sequence of Tasks by Reviewing Current Method or
tri
Procedures (the Way It Is Supposed to Be Done).
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4. Observe the Process (the Way It Is Actually Being Done).

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5. Identify Errors - Gaps Between #3 and #4 - the Differences

ac
Between How We Should Do It and How We Actually Do It

fM
(Theory Vs. Actual).

pd
6. Identify Mistake Proof Device(s) Required to Prevent or

Detect Error Conditions.
7. Trial and Error Perfection of Original Mistake-proof Device
Until Solution Eliminates Defect.
Types of Mistake-Proof Devices
A list of Mistake-proof devices, certainly not all inclusive, that can be
n
used to respond to Red Flags and prevent errors and/or defects:
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1. Guide / Reference / Interference Other Prevention Techniques:
Rod or Pin
al 1. Eliminate the Condition
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2. Template
2. Redesign for Symmetry
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3. Limit Switch / Microswitch

4. Counter 3. Redesign for Asymmetry
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5. Odd-part-out Method
fM
6. Sequence Restriction
Mistake-proof Your Mistake-
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7. Standardize and Solve proof

8. Critical Condition Indicator
9. Detect Delivery Chute
10. Stopper / Gate
11. Sensor

Detecting and Avoiding Defects
What are the Five Best Mistake-Proof Devices?
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Human errors are usually inadvertent. Mistake-proof devices
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help us avoid defects, even when inadvertent errors are made.
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Mistake-proofing helps build quality into processes.
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Here are five examples of mistake-proofing for detecting or
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avoiding defects caused by human errors.
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UPPER DIE
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Guide Pins of Different

1
ac
Sizes
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GUIDE PINS
LOWER DIE
pd
Error Detection and

2 Alarms

Detecting and Avoiding Defects - cont...
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3 Limit Switches
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PRESS
LIMIT SWITCH DETECTS
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CORRECT PLACEMENT
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PRODUCT
TO OPERATING
al CIRCUIT
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CLEAR BUTTON
4
ac
Counters
fM
DIGITAL COUNTER
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5 Checklists

Mistake Proofing Example
Before Mistake-Proofing
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After Mistake-Proofing
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Locating
Angles
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Locating
Angles
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Correct
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Locating Guide Pin

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Angles
Incorrect

Before Mistake-Proofing After Mistake-Proofing
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Omitted Washer
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Container
During assembly, lockwashers are frequently The correct number of each part required for the
omitted. Without the lockwashers, the bolts can operation is precounted and provided in a
loosen. container.
n
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Correct Fire
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Hose to Area B Hose to Area A
Extinguisher
Reservoir Hose to Area A
Bottles al
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Fire
ne
Extinguisher
Reservoir
Hose to Area B
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Bottles
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Incorrect
fM
Fire
Extinguisher
Reservoir Hose to
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Female Male
Bottles Area B
Different size
connectors
Hose to Area A
By redesigning the connectors to two different

Hose connections can be reversed. If a fire
sizes and types (female and male), it is no
occurred in Area A, Area B would be doused.
longer possible to mix up hose connections.

n
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Manual measuring and layout of trim periphery
rs
Locating
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Holes
Panel Trim
Lines al
tri
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Trim
Template
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Panel Trim
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Locating
Lines
Holes
fM
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Results in inaccurate location of trim lines, Use of template allows accurate layout of trim
creating a defective part when the part is lines.
trimmed.
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al
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The cause of the trouble was scrutinized and

Covers were frequently scratched when the screwdrivers a change was made in the shape of the screw
slipped out of the screw slot and slid against the plastic slot to prevent the screwdriver from slipping.
covers. Scratches caused by the screwdriver slipping
have been completely eliminated.

Poka-yoke Example 1
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 Screw driver slips

and scratches the
product. Source: “Poka-yoke Daizukan” Nikkan-kogyo
1
Poka-yoke Example 2
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al Fool-proof device
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Non-defective
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Defective
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pd
Source: “Poka-yoke Daizukan” Nikkan-kogyo

Analysis of Carelessness
Kanebo Chemical, 1989
n
io
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Wrong operations 23%

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Negligence 48%
(Forgetfulness)
Source: “Poka-yoke activities“ Kanebo Chem.,1991
Auto-nomation (Jidoka)
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
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Jidoka refers to the ability of production
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equipment, including a single machine,
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to sense a malfunction of the machine.

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pd

Autonomation (Jidoka): Automation
with a human touch
n
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Stop! I don’t know.
al
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Jidoka Simple automation
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pd

1
Single minute exchange of die
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(SMED)
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rs
ve
al
 The
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goal of single minute set-up
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movement is to reduce the set-

hi
ac
up time to less than 10 minutes.

fM
pd

Stamping Machine
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al
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The Trick of the Magic
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Advanced Preparation
1
Masking
tape Paint an arrow
n
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al
tri
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Trash can Spreadsheet

hi
ac
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pd
Example (1) Source: The Japan HR Association

U-shaped washer Nut and bolt
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Pear-shaped holes
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Source: H. Hirano “Me de mite wakaru JIT Seisan Hoshiki” Nikkan-kogyo Shinbun,
Example (2)
Seven Wastes
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1. Waste from over-production
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2. al
Waste of waiting time
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3. Transportation waste
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4. Processing waste
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5. Inventory waste
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6. Waste of motion
7. Waste from product defectives
2

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n

Hasan Haider, NPO Pakistan 1

“Cheaper” “Faster” “Better”

Hasan Haider, NPO Pakistan 2

 Toyota Production System

Hasan Haider, NPO Pakistan 4

 Need to do more than talk.

 Improvements don’t have to be expensive.

Hasan Haider, NPO Pakistan 5

A strategic focus to economically make

Hasan Haider, NPO Pakistan 7

Result: Shorter Reduced lead time

Hasan Haider, NPO Pakistan 8

 Don’t substitute money for brains.

 Ask “Why?”, five times.

Improvement is not made from a conference

3) Regulate amount of inventory in the

4) Provide a visual control that makes

4) Never pass a known defect downstream.

5) Use gradual kanban reductions to drive improvement.

Hasan Haider, NPO Pakistan 11

• Limits inventory • Box

Hasan Haider, NPO Pakistan 12

Total Time x Production Requirement = Units in Pipeline

Units per Kanban

Hasan Haider, NPO Pakistan 13

Kanban Work Kanban Work Kanban

Hasan Haider, NPO Pakistan 16

just when they are needed,

in just the amount needed,

at all stages of production.

Hasan Haider, NPO Pakistan 18

This refers to the thoughtful use of

devices which eliminates operator’s

Hasan Haider, NPO Pakistan 19

prevents mistakes before they

Hasan Haider, NPO Pakistan 20

Recognizes People Forget and Make Errors

 Uses Common Sense (Mistake Proofing) Ideas

and Methods in Product and Process Design to

Hasan Haider, NPO Pakistan 21

Improve schedule performance (especially

in relation to the predictability of cycle

 “Zero” Quality Control (Zero Defects)

doing the wrong things Reduces or

in the wrong order in the

wrong way  Improves morale

Hasan Haider, NPO Pakistan 23

Removed From the Ignition Switch

 Turn Signal Warning Beep When Left on

Hasan Haider, NPO Pakistan 24

Panels Are Removed

Thermostat Which Prevents “Heat”

and “Cool” From Being Turned on at

the Same Time

Hasan Haider, NPO Pakistan 25

– Fire Drills, Safe Exit Plans

– Pressure Switches, Monitors

– Panic Door Hardware on All Exterior Doors

– Fixtures Which Prevent Parts From Being

Hasan Haider, NPO Pakistan 26

 Lean Manufacturing Will Not Tolerate Mistakes

John Foster 3-21-92