2nd Edition

JIT Implementation Manual -- The Complete Guide to Just-In-Time Manufacturing
Volume 4 -- Leveling -- Changeover and Quality Assurance

ISBN 9781420090284
Published April 27, 2009 by Productivity Press
188 Pages 145 B/W Illustrations

USD $49.95

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Book Description

"It is a book for manufacturing companies that are fighting desperately for survival and that will go to any length to improve their factories and overcome the obstacles to success. One could even call this book a ‘bible’ for corporate survival."

—Hiroyuki Hirano


Known as the JIT bible in Japan, JIT Implementation Manual — The Complete Guide to Just-in-Time Manufacturing presents the genius of Hiroyuki Hirano, a top international consultant with vast experience throughout Asia and the West. Encyclopedic in scope, this six-volume practical reference provides unparalleled information on every aspect of JIT— the waste-eliminating, market-oriented production system. This historic, yet timeless classic is just as crucial in today’s fast-changing global marketplace as when it was first published in Japan 20 years ago.

Volume 4: Leveling — Changeover and Quality Assurance provides essential background on the core concept of level production in a JIT, or lean, manufacturing system and the implementation techniques. It also discusses changeover and the rules and procedures for changeover improvement and covers quality assurance in the context of level production, including how to recognize structures that create defects, plan for achieving zero defects, and make use of mistake-proofing devices.

Table of Contents

What Is Level Production?
Various Ways to Create Production Schedules
Differences between Shish-Kabob Production and Level Production
Leveling Techniques
Realizing Production Leveling

Why Is Changeover Improvement (Kaizen) Necessary?
What Is Changeover?
Procedure for Changeover Improvement
Seven Rules for Improving Changeover

Quality Assurance
Quality Assurance: The Starting Point in Building Products
Structures that Help Identify Defects
Overall Plan for Achieving Zero Defects
The Poka-Yoke System
Poka-Yoke Case Studies for Various Defects
How to Use Poka-Yoke and Zero Defects Checklists

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JIT Management Laboratory, Tokyo, Japan