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    Reduced W-I-P Exposes Problems

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    aroundthecape

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    Reduced W-I-P Exposes Problems

    Uploaded by

    aroundthecape
    46 views9 pages

    Original Title

    JIT

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    © Attribution Non-Commercial (BY-NC)

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    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    46 views9 pages

    Reduced W-I-P Exposes Problems

    Uploaded by

    aroundthecape

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 9

    Increased return on investment

    Cost reduction through


    Better adaptability reduced
    Quality improvement
    to market Inventories mainly, and other
    unnecessary things

    Just-in-time production

    Vendors Smoothing of production Kanban Information system

    Yo-i-don
    Reduced Suitable
    Small pacing, quality
    W-I-P equipment &
    lot size consciousness
    Exposes layout
    & teamwork
    problems
    Short Multifunction Standardized
    Setup worker Jobs
    Time
    Problem
    Solving by
    Labour & mgt
    Through quality
    Circles, etc.
    Lucas TVS
    • Lucas - TVS established in 1961 as a joint venture between
    Lucas UK and T V Sundram Iyengar & Sons (TVS), India to
    manufacture Automotive Electrical Systems. Lucas-TVS is the
    leader in Auto Electricals in India today with 48 years
    experience in design and manufacturing. 4 out of 5 vehicles
    rolled out daily are fitted with Lucas-TVS products.

    • First JIT Grand Prix winner outside Japan and Korea in 2003,
    awarded by JIT management Laboratory Co. Japan. The award
    is given to a company that has successfully adopted and
    practiced JIT techniques over the years.

    • JIT implementation began in 1985, much ahead of several


    other manufacturers in India.
    Manufacturing Organization
    Lucas TVS

    Five Step process

    • Step 1: Building awareness among


    employees.
    • Step 2: 5S for factory improvement.
    • Step 3: Flow manufacturing.
    • Step 4: Levelling.
    • Step 5: Standardised operations.
    Methodology
    Manufacturing Journey
    Lucas TVS
    • By implementing Kanban, inventory in the system was reduced even when
    production was increasing and better control of processes was possible. Eg:
    Wiper motor cell would receive parts such as motor and casing only when
    it sent a Kanban card to the internal supplier.
    • Lean and efficient operation at Lucas.
    • Better prepared to absorb sudden changes in customer order, drop in
    demand or even price pressures.
    • Sales per employee increased from Rs. 1.96 lakh at the time the JIT
    implementation process began to Rs. 13.80 lakh in 2002.
    • Rejection rates came down from 10 percent to below 1 percent.
    • Scrap rate is at 0.8 percent compared to 3 percent.
    • Employees make 400 suggestions every month.
    Journey Towards Excellence

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