Final

A presentation on implementation of
JIT production through kanban

system
 GUIDED BY PRESENTATED BY
 Mr. K. SRIDHAR RITESH SHRIVASTAV
CONTENTS
 Introduction.
 History.
 Objectives.
 Types of wastes.
 Factors affecting .
 Methodology
 Implementation
 Results
 Changes after implementation.
 conclusion
INTRODUCTION OF JUST IN TIME
 Just-In-Time is defined as "the production of the

minimum number of different units, in the
smallest possible quantities, at the latest possible
time, thereby eliminating the need for inventory.
 JIT does not mean to produce on time, but to

produce just in time
HISTORY OF JIT
 JIT was invented by Taiichi Ohno of Toyota
shortly after World War II. Ohno's system was
designed to handle large or small volumes of a
variety of parts. the Toyota production system was
developed and refined between 1945 and 1970.
OBJECTIVES
SEVEN BASIC TYPES OF WASTE
ELIMINATED BY JIT
 Transportation waste
 Process Waste
 Inventory Waste
 Waste of motion
 Waste from product defects
 Waiting time
 Overproduction
COMMON CAUSES OF WASTE
 Layout (distance)  Inconsistent
 Long setup time performance measures
 Ineffective production
 Incapable processes planning
 Poor maintenance  Lack of workplace
 Poor work methods organization
 Lack of training  Poor supply
quality/reliability
FACTORS EFFECTING
IMPLIMENTATION OF JIT IN AN
ORGANISATION
JUST-IN-TIME TECHNIQUES
 Pull method of material flow.

 Set up time reduction.
 Close relationship with supplier.
 Preventive maintenance.
 Cellular manufacturing.
 Kanban system.
KANBAN SYSTEM
TYPES OF KANBAN CARD
SYSTEM
 Kanban is an information system that is used to
control the number of parts to be produced in
every process.
 The most common types of kanbans are the
withdrawal kanban, which specify the quantity
that the succeeding process should pull from the
preceding process.
 And the production kanban, which specifies the
quantity to be produced by the proceeding process
METHODOLOGY
 When we implemented kanban system in any
organization the following steps we follows.
 Conduct data collection.
 Calculate the kanban size.
 Design the kanban.
 Train everyone.
 Start the kanban.
 Audit & maintain the kanban.
 Improve the kanban.
 When we implemented kanban system in bhilai
steel plant ,the following term & formulae we are
used :
 Adjusted production requirements= [avg.
production order/(1- system scrap)]
 Available time=[total time in a shift- (planned &
unplanned down time)]
 Time required for production=[sum * (adjusted
production requirement * cycle time per part)]
 Time available for changeovers= [total available
time- time required for production]
 Replenishment interval= [total time required for
changeovers – total time available for changeover]
 Container quantity = [(buffer quantity +
replenishment interval quantity) / container size]
IMPLEMENTATION
 In Bhilai steel plant, we consider the three
operations on a work piece at machine shop
(mars1) for making gears. The timing of all the
operations are given at table below.
Machine Operation Runtime(in
minute)
M1 Facing/turning 35
M2 Keyway marking 5
M3 Gear cutting 60
Kanban card system for gear cutting
process
M1 M2 M3 Final
product
storage storage
Production kanban
Move kanban
CALCULATIONS
 Time required for changeover per part = 45
minutes
 Planned downtime = 50 minutes (i.e. lunch)
Machine Runtime(in minutes)

M1 35
M2 5
M3 60
 Production cycle per part = 35+5+60= 100
min./part
 Total time in shift = 8*60 = 480 minutes
 Available time for production = (total time in a
shift – planned downtime)
480 minutes – 50 minutes = 430 minutes
 Total available time for changeover = 430-(100*3)
= 130 minutes
 Total time required for changeover = 45*3=135
minutes.
 Replenishment interval =135/130=1.03
(For smooth flow we take 2)
 Before applying kanban system in machine shop
Taking 3 parts produced by workers/organization
per shift.
 But if we implemented kanban system in machine
shop or (MARS 1) the shift is like this.
Part no. M1-in M1-out M2-in M2-out M3-in M3-out
1 10 45 62 67 82 142
2 55 90 107 112 127 187
3 100 135 152 157 172 232
4 151 188 203 208 313 375
5 198 235 250 255
6 245 282 328 333
7 292 329
8 339 376
RESULTS
 on implementing kanban 40 minutes of extra spare time is
left per shift for production on purpose. On other way, 40
minute per shift is well saved by kanban system for more
work.
 Scrap obtaining from machining process for every part is
very well accomplished by the kanban system thus
descends the scrap & control the scrap management
 With an effective conclusive result a time span of 14
hours/week is well being saved by implementing kanban
system in the MARS1 of BSP.
CHANGES AFTER
IMPLEMENTATION OF JIT
 Reduction in work in progress and inventory.
 Reduction in set up time.
 Defect free production.
 Lower investment in inventory.
 Lesser cost of production.
 Reduction in wastage and rework.
CONCLUSION
 The research findings show that kanban system is
essential in ensuring the success of just in time
production & create smooth flow of part
throughout manufacturing system.
 The implementation shows that lead time, in
process & finished goods inventory & also
finished good area will certainly improve.
 implementation of kanban system has improved
manufacturing system & this should be part of the
core task of JIT practitioner.
REFERENCES
 Vikas Kumar / international journal of engineering science & technology, vol.2 (1),
2010, pp 40-42.
 Wafa, m & yasin, m.(2011). A conceptual framework for effective implementation of
JIT international journal of operations & production management, 118 (11/12), 1111-
1124.
 C.s Kumar & r. panneerselvam”literature review of JIT kanban system “international
journal of advanced manufacturing technology,32(3-4),pp-393-408
 Garg.s, vart p. & kanda A, 2009”work culture in JIT environment, vol.35, no-3, pp-463-
466.
 Fiedler k., galletly J.E & bicheno J., 2007”expert advice for JIT implementation
“international journal of operations & production management, vol.13, pp23-30.
 Ajit singh, 2011”just in time system, an integrated system”, productivity journal, vol.30,
no.3, pp-309-314.
 N.singh, k shek & d. meloche”the development of a kanban system, a case study
“international journal of operation & production management, 10(7), pp-28-36.
Thank-you

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A presentation on implementation of

JIT production through kanban

 Just-In-Time is defined as "the production of the

 JIT does not mean to produce on time, but to

 Pull method of material flow.

Machine Runtime(in minutes)

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