JIT Implementation Manual, 6-Volume Set: The Complete Guide to Just-In-Time Manufacturing (Paperback, 2)

Foreword

Introduction

Production Management and JIT Production Management

Approach to Production Management

Overview of JIT Production System

Destroying Factory Myths: A Revolutionary Approach

Relations Among Sales Price, Cost, and Profit

Ten Arguments Against the JIT Production Revolution

Approach to Production as a Whole

Approach to Efficiency

Approach to Waste

Approach to Inventory and Lead-Time

Approach to Equipment

Approach to Inspection and Management

Approach to Promoting Improvements

"Wastology": The Total Elimination of Waste

Why Does Waste Occur?

Types of Waste

How to Discover Waste

How to Remove Waste

Secrets for Not Creating Waste

The "5S" Approach

What are the 5S’s?

Red Tags and Kanban: Proper Arrangement and Orderliness Made Visible

The Red Tag Strategy for Visual Control

The Signboard Strategy: Visual Orderliness

Orderliness Applied to Jigs and Tools

Flow Production

Why Inventory is Bad

What is Flow Production?

Flow Production Within the Factory

Flow Production Between Factories

Multi-Process Operations

Multi-Process Operations: A Wellspring for Humanity on the

Job

The Difference between Horizontal Multi-Unit Operations and Vertical Multi-Process Operations

Questions and Key Points about Multi-Process Operations

Precautions and Procedures for Developing Multi-Process

Operations

Labor Cost Reduction

What is Labor Cost Reduction?

Labor Cost Reduction Steps

Points for Achieving Labor Cost Reduction

Visible Labor Cost Reduction

Kanban

Differences between the Kanban System and Conventional

Systems

Functions and Rules of Kanban

How to Determine the Variety and Quantity of Kanban

Administration of Kanban

Visual Control

What is Visual Control?

Case Study: Visual Orderliness

Standing Signboards

Andon: Illuminating Problems in the Factory

Production Management Boards: At-a-Glance Supervision

Relationship between Visual Control and Kaizen

Leveling

What is Level Production?

Various Ways to Create Production Schedules

Differences between Shish-Kabob Production and Level

Production

Leveling Techniques

Realizing Production Leveling

Changeover

Why is Changeover Improvement (Kaizen) Necessary?

What is Changeover?

Procedure for Changeover Kaizen

Seven Rules for Improving Changeover

Quality Assurance

Quality Assurance: The Starting Point in Building Products

Structures that Create Defects

Overall Plan for Achieving Zero Defects

The Poka-Yoke System

Poka-Yoke Case Studies for Various Defects

How to Use Poka-Yoke/Zero Defect Checklists

Standard Operations

Overview of Standard Operations

How to Establish Standard Operations

How to Make Combination Charts and Standard Operation

Charts

Standard Operations and Operation Improvements

How to Preserve Standard Operations

Jidoka: Human Automation

Steps Toward Jidoka

The Difference Between Automation and Jidoka

Separating Workers: Separating Human Work from Machine

Work

Ways to Prevent Defects

Extension of Jidoka to the Assembly Line

Maintenance and Safety

Existing Maintenance Conditions on the Factory Floor

What is Maintenance?

CCO: Three Lessons in Maintenance

Preventing Breakdowns

Why do Injuries Occur?

What is Safety?

Strategies for Zero Injuries and Zero Accidents

JIT Forms

Overall Management

JIT Management Diagnostic List

Five Stages of JIT Production and JIT Radar Charts

Waste-Related Forms

Arrow Diagrams

General Flow Analysis Charts

Operations Analysis Charts

Waste-Finding Checklist (Process- and Type-

Specific)

5W1H Sheet

5S-Related Forms

5S Checklist (for Factories)

5S Checklist (for Workshops) and 5S Radar Charts

5S Memos

Red Tags

Red Tag Campaign Reports

Lists of Unneeded Inventory and Equipment

Cleaning Checklist

Five-Point Checklist to Access Cleaned-Up Status

Display Boards

Engineering-Related Forms

P-Q Analysis Lists and PQ Analysis Charts

Process-Route Diagrams

Line Balance Analysis Charts

Cooperation Operation Confirmation Chart

Delivery Company Evaluation Charts

JIT Delivery Efficiency Lists

Multiple Skills Training Schedule

Multiple Skills Achievement Chart

Production Management Boards

Model and Operating Rate Trend Charts

Public Changeover Timetables

Changeover Improvement Lists

Changeover Work Procedure Analysis Charts

Changeover Results Table

5S Checklist for Changeover

Poka-Yoke/Zero Defects Checklist

Parts-Production Capacity Work Table

Standard Operations Combination Charts

Summary Table of Standard Operations

Work Methods Table

Standard Operations Forms

JIT Introduction-Related Forms

JIT’s Ten Commandments

Improvement Memos

List of JIT Improvement Items

Improvement Campaign Planning Sheet

Improvement Result Charts

Weekly Report on JIT Improvements

JIT Leaders’ Report

About the Authors

Index