Table Of ContentBusiness Improvement H
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JIT Implementation Manual
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The Complete Guide to Just-in-Time Manufacturing • Second Edition
Volume 1
J
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The Just-in-Time Production System
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HIROYUKI HIRANO
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“It is a book for manufacturing companies that are fighting desperately for survival and that will go t
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to any length to improve their factories and overcome the obstacles to success. One could even call t
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this book a ‘bible’ for corporate survival.”
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—Hiroyuki Hirano M
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Known as the JIT bible in Japan, JIT Implementation Manual — The Complete Guide to Just-in-
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Time Manufacturing presents the genius of Hiroyuki Hirano, a top international consultant with vast
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experience throughout Asia and the West. Encyclopedic in scope, this six-volume practical reference
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provides unparalleled information on every aspect of JIT— the waste-eliminating, market-oriented c
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production system. This historic, yet timeless classic is just as crucial in today’s fast-changing global n
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marketplace as when it was first published in Japan 20 years ago. E
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Providing a comprehensive introduction to the just-in-time production system, Volume 1: The i
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n
Just-in-Time Production System dispels outdated myths and ideas about manufacturing that are
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still prevalent. Supplying essential background information on the JIT approach to production
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management, this user-friendly resource builds a strong foundation for implementation.
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PP9016 1
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JIT Implementation Manual
The Complete Guide to
Just-in-Time Manufacturing
Second Edition
Volume 1
JIT Implementation Manual
The Complete Guide to
Just-in-Time Manufacturing
Second Edition
Volume 1
The Just-in-Time Production System
HIROYUKI HIRANO
Originally published as Jyasuto in taimu seisan kakumei shido manyuaru copyright © 1989 by JIT Management Laboratory Company, Ltd., Tokyo, Japan.
English translation copyright © 1990, 2009 Productivity Press.
CRC Press
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Version Date: 20140812
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Contents
Publisher’s Message .......................................................................ix
Foreword to the Original English Edition ......................................xi
Introduction to the Original English Edition ...............................xiii
Volume 1
1 Production Management and JIT Production Management ......1
Approach to Production Management .................................................. 3
Overview of the JIT Production System ............................................... 7
Introduction of the JIT Production System ..........................................12
2 Destroying Factory Myths: A Revolutionary Approach ........... 35
Relations among Sales Price, Cost, and Profit......................................35
Ten Arguments against the JIT Production Revolution ........................40
Approach to Production as a Whole ...................................................44
Index .............................................................................................I-1
About the Author .........................................................................I-31
Volume 2
3 “Wastology”: The Total Elimination of Waste .........................145
Why Does Waste Occur? ...................................................................146
Types of Waste .................................................................................151
How to Discover Waste ....................................................................179
How to Remove Waste .....................................................................198
Secrets for Not Creating Waste ..........................................................226
4 The “5S” Approach .................................................................237
What Are the 5S’s? ............................................................................237
Red Tags and Signboards: Proper Arrangement and
Orderliness Made Visible ..................................................................265
v
vi ◾ Contents
The Red Tag Strategy for Visual Control ...........................................268
The Signboard Strategy: Visual Orderliness ......................................293
Orderliness Applied to Jigs and Tools ...............................................307
Volume 3
5 Flow Production .....................................................................321
Why Inventory Is Bad .......................................................................321
What Is Flow Production? .................................................................328
Flow Production within and between Factories ................................332
6 Multi-Process Operations ...................................................... 387
Multi-Process Operations: A Wellspring for Humanity on the Job .....387
The Difference between Horizontal Multi-Unit Operations and
Vertical Multi-Process Operations .....................................................388
Questions and Key Points about Multi-Process Operations ...............393
Precautions and Procedures for Developing Multi-Process
Operations ........................................................................................404
7 Labor Cost Reduction .............................................................415
What Is Labor Cost Reduction? .........................................................415
Labor Cost Reduction Steps ..............................................................419
Points for Achieving Labor Cost Reduction .......................................422
Visible Labor Cost Reduction ............................................................432
8 Kanban ................................................................................. 435
Differences between the Kanban System and Conventional Systems ...435
Functions and Rules of Kanban .......................................................440
How to Determine the Variety and Quantity of Kanban ..................442
Administration of Kanban ................................................................447
9 Visual Control ........................................................................ 453
What Is Visual Control? .....................................................................453
Case Study: Visual Orderliness (Seiton) .............................................459
Standing Signboards .........................................................................462
Andon: Illuminating Problems in the Factory ...................................464
Production Management Boards: At-a-Glance Supervision ................470
Relationship between Visual Control and Kaizen .............................471
Contents ◾ vii
Volume 4
10 Leveling ..................................................................................475
What Is Level Production?.................................................................475
Various Ways to Create Production Schedules ..................................477
Differences between Shish-Kabob Production and Level Production ....482
Leveling Techniques .........................................................................485
Realizing Production Leveling ...........................................................492
11 Changeover ............................................................................ 497
Why Is Changeover Improvement (Kaizen) Necessary? ....................497
What Is Changeover? ........................................................................498
Procedure for Changeover Improvement ..........................................500
Seven Rules for Improving Changeover ............................................532
12 Quality Assurance ................................................................. 541
Quality Assurance: The Starting Point in Building Products .............541
Structures that Help Identify Defects ................................................546
Overall Plan for Achieving Zero Defects ...........................................561
The Poka-Yoke System ......................................................................566
Poka-Yoke Case Studies for Various Defects ......................................586
How to Use Poka-Yoke and Zero Defects Checklists .........................616
Volume 5
13 Standard Operations ............................................................. 623
Overview of Standard Operations ....................................................623
How to Establish Standard Operations .............................................628
How to Make Combination Charts and Standard Operations Charts ....630
Standard Operations and Operation Improvements ..........................638
How to Preserve Standard Operations ..............................................650
14 Jidoka: Human Automation ................................................... 655
Steps toward Jidoka ..........................................................................655
The Difference between Automation and Jidoka ..............................657
The Three Functions of Jidoka .........................................................658
Separating Workers: Separating Human Work from Machine Work ....660
Ways to Prevent Defects ...................................................................672
Extension of Jidoka to the Assembly Line .........................................676
