AN INVESTIGATION INTO PRODUCT DESIGN AND PRODUCTION TECHNIQUES WITHIN A JUST-IN-TIME MANUFACTURING ENVIRONMENT

Abstract

This thesis describes the implementation of a Just-in-Time (JIT) cell on a greenfield site. It concentrates on a before and after implementation situation. Various production parameters are analysed to compare flowline performance before and after the implementation of JIT. The study is primarily concerned with the philosophies behind the Japanese management style of JIT and the practical use of JIT in a relatively small production line. Each area of JIT and its associated components are studied and, where practical, executed into practice within the production line. The study includes an investigation of the present manufacturing system and recommends improvements to aid manufacturing output. Total Quality Control, Set-up Reduction, Group Technology, Kanban, Failure Mode and Effects Analysis and Value Analysis are tools used to assist the formation of the JIT cell. Results taken after implementation revealed that stock levels reduced by 25%. Shop floor area was reduced by 205 square metres and lead time reduced by 33%. Large arrears in orders were virtually eliminated six weeks after implementation. Warranty claims were greatly reduced. Quality Management greatly enhanced the product and cross-training of operatives was achieved.