及時化生產系統及時化生產系統 11
及時化(just in time，JIT)概述
提出者：豐田汽車副社長，大野耐一
(Taiichi Ohno)。
意義
將需要的將需要的物品物品在必須的在必須的時間時間供應必須的供應必須的品質品質與與
數量數量到需要的到需要的地點地點。。
目的
消除混亂消除混亂
使系統彈性化使系統彈性化
降低籌置與前置時間降低籌置與前置時間
存量最小化存量最小化
消除浪費消除浪費
及時化生產系統及時化生產系統 22
JIT目標和建築架構的歸納
產品設計 流程設計 人員因素 製造規劃
避免中斷
使系統有彈性
排除浪費
平衡
迅速的流程
最終目標
支援目標
建築架構
及時化生產系統及時化生產系統 33
常見的資源浪費1
超額生產(overproduction)
等候時間(waiting time)
不必要的運送(unnecessary
transporting)
存貨(inventory)
加工浪費(processing waste)
不必要的生產步驟不必要的生產步驟
產出瑕疵品產出瑕疵品
及時化生產系統及時化生產系統 44
常見的資源浪費2
無效的工作方法(inefficient work
method)
不佳的佈置和物料搬運模式，增加在製品不佳的佈置和物料搬運模式，增加在製品
存貨存貨
產品不良
再製成本再製成本
消費者不滿意造成銷售損失消費者不滿意造成銷售損失
及時化生產系統及時化生產系統 55
Waste in Operations
及時化生產系統及時化生產系統 66
Waste in Operations
及時化生產系統及時化生產系統 77
Waste in Operations
及時化生產系統及時化生產系統 88
The Principles of the TOYOTA
Production System (TPS)1
All work must be completely specified as to
content, sequence, timing, and outcome.
Every customer-supplier connection must
be direct, unambiguously specifying the
people involved, the form and quantity of
the services or goods to be provided, the
way the requests are made by each
customer, and the expected time in which
the requests will be met.
及時化生產系統及時化生產系統 99
The Principles of the TOYOTA
Production System (TPS)2
The pathway for every service and
product must be simple and direct.
Any improvement to the system must
be made in accordance with the
scientific method, under the guidance
of a teacher, at the lowest possible
organizational level.
及時化生產系統及時化生產系統 1010
Basic Elements of JIT1
標準的零件標準的零件((產品設計產品設計))
模組化設計模組化設計((產品設計產品設計))
高產能的系統高產能的系統((產品設產品設
計計))
可同時生產可同時生產((產品設計產品設計))
將員工視為資產將員工視為資產((人員人員//
組織的要素組織的要素))
訓練員工，使其變成多訓練員工，使其變成多
能工能工((人員人員//組織的要素組織的要素))
持續改善持續改善((人員人員//組織的組織的
要素要素))
成本會計成本會計((人員人員//組織的組織的
要素要素))
領導與專案管理領導與專案管理((人員人員//
組織的要素組織的要素))
及時化生產系統及時化生產系統 1111
Basic Elements of JIT2
Cellular layouts (Cellular layouts (製程製程
設計設計
Pull production Pull production
system(system(製造規劃與控製造規劃與控
制制))
Flexible resources (Flexible resources (製製
程設計程設計))
Kanban production Kanban production
control(control(製造規劃與控制製造規劃與控制
))
Small-lot productionSmall-lot production
((製程設計製程設計))
Quick setups (Quick setups (製程設製程設
計計))
Uniform production Uniform production
levels (levels (製造規劃與控制製造規劃與控制))
Quality at the sourceQuality at the source
((製程設計製程設計))
Total productive Total productive
maintenance (maintenance (製造規劃製造規劃
與控制與控制))
Supplier networks(Supplier networks(製製
造規劃與控制造規劃與控制))
及時化生產系統及時化生產系統 1212
Flexible Resources
Multifunctional workers (多能工)
Perform more than one job
General purpose machines (通
用設備)
Perform several basic functions
Study operators & improve
operations
及時化生產系統及時化生產系統 1313
Cellular Layouts
Group dissimilar machines in
manufacturing cell to produce
family of parts
Work flows in one direction
through cell
Cycle time adjusted by changing
worker paths
及時化生產系統及時化生產系統 1414
Manufacturing Cell with Worker
Routes
Worker
1
Worker
2
Worker
3
Cell 1
及時化生產系統及時化生產系統 1515
Worker Routes Lengthened as
Volume Decreases
Cell 5
Worker
2
Cell 2
Worker
1
Cell 1
Worker
3
Cell 3 Cell 4
及時化生產系統及時化生產系統 1616
推式與拉式系統
推式系統(push system)(例如，MPR)
當工作在某工作站完成時，產出就被推往下一當工作在某工作站完成時，產出就被推往下一
站。站。
拉式系統(pull system)(例如，JIT)
工作移動的控制落於下一站工作移動的控制落於下一站;;每一工作站從前一每一工作站從前一
站拉拔所需產出。站拉拔所需產出。
及時化生產系統及時化生產系統 1717
Kanban Production Control System
(看板生產管制系統)
Kanban card indicates standard quantity of
production
Derived from two-bin inventory system(雙倉
制)
Kanban maintains discipline of pull
production
Production kanban(生產看板) authorizes
production
Withdrawal kanban(提領看板) authorizes
movement of goods
及時化生產系統及時化生產系統 1818
A Sample Kanban
及時化生產系統及時化生產系統 1919
The Origin of Kanban
a) Two-bin inventory system b) Kanban inventory system
Reorder
card
Bin 1
Bin 2
Q - R
Kanban
RR
Q = order quantity
R = reorder point - demand during lead time
及時化生產系統及時化生產系統 2020
Types of Kanbans —
Dual kanbans
及時化生產系統及時化生產系統 2121
Single-Card Kanban System
Receiving post
Kanban card for
product 1
Kanban card for
product 2
Fabrication
cell
O1
O2
O3
O2
Storage
area
Empty containers
Full containers
Assembly line 1
Assembly line 2
及時化生產系統及時化生產系統 2222
Storage Storage
areaarea
Empty containersEmpty containers
Full containersFull containers
Single-Card Kanban System
Receiving postReceiving post
Kanban card for Kanban card for
product 1product 1
Kanban card for Kanban card for
product 2product 2
Fabrication Fabrication
cellcell
OO11
OO22
OO33
OO22
Assembly line 1Assembly line 1
Assembly line 2Assembly line 2
及時化生產系統及時化生產系統 2323
Storage Storage
areaarea
Empty containersEmpty containers
Full containersFull containers
Single-Card Kanban System
Receiving postReceiving post
Kanban card for Kanban card for
product 1product 1
Kanban card for Kanban card for
product 2product 2
Fabrication Fabrication
cellcell
OO11
OO22
OO33
OO22
Assembly line 1Assembly line 1
Assembly line 2Assembly line 2
及時化生產系統及時化生產系統 2424
Storage Storage
areaarea
Empty containersEmpty containers
Full containersFull containers
Single-Card Kanban System
Receiving postReceiving post
Kanban card for Kanban card for
product 1product 1
Kanban card for Kanban card for
product 2product 2
Fabrication Fabrication
cellcell
OO11
OO22
OO33
OO22
Assembly line 1Assembly line 1
Assembly line 2Assembly line 2
及時化生產系統及時化生產系統 2525
Storage Storage
areaarea
Empty containersEmpty containers
Full containersFull containers
Single-Card Kanban System
Receiving postReceiving post
Kanban card for Kanban card for
product 1product 1
Kanban card for Kanban card for
product 2product 2
Fabrication Fabrication
cellcell
OO11
OO22
OO33
OO22
Assembly line 1Assembly line 1
Assembly line 2Assembly line 2
及時化生產系統及時化生產系統 2626
Storage Storage
areaarea
Empty containersEmpty containers
Full containersFull containers
Single-Card Kanban System
Receiving postReceiving post
Kanban card for Kanban card for
product 1product 1
Kanban card for Kanban card for
product 2product 2
Fabrication Fabrication
cellcell
OO11
OO22
OO33
OO22
Assembly line 1Assembly line 1
Assembly line 2Assembly line 2
及時化生產系統及時化生產系統 2727
Storage Storage
areaarea
Empty containersEmpty containers
Full containersFull containers
Single-Card Kanban System
Receiving postReceiving post
Kanban card for Kanban card for
product 1product 1
Kanban card for Kanban card for
product 2product 2
Fabrication Fabrication
cellcell
OO11
OO22
OO33
OO22
Assembly line 1Assembly line 1
Assembly line 2Assembly line 2
及時化生產系統及時化生產系統 2828
看板系統 — single kanban
及時化生產系統及時化生產系統 2929
Dual kanban vs. single kanban
Dual kanban
Is used when material is not necessarily Is used when material is not necessarily
moving between two consecutive moving between two consecutive
processes, or when there is more than one processes, or when there is more than one
input to a process and the inputs are input to a process and the inputs are
dispersed throughout the throughout the facility.
Single kanban
Is used when the processes are tightly Is used when the processes are tightly
.
及時化生產系統及時化生產系統 3030
Types of Kanbans
Kanban Square
Marked area designed to hold items
Signal Kanban
Triangular kanban used to signal
production at the previous workstation
Material Kanban
Used to order material in advance of a
process
Supplier Kanbans
Rotate between the factory and suppliers
及時化生產系統及時化生產系統 3131
Types of Kanbans —
kanban square and kanban racks
及時化生產系統及時化生產系統 3232
Types of Kanbans —
signal kanbans
及時化生產系統及時化生產系統 3333
看板管理系統之規則
不要把不良品交給後製程。
由後製程到前製程來領取零件。
前製程僅生產將被後製程領用去的數量。
生產必須平衡。
看板只做為微調整的手段，其張數必須減
到最少。
製程必須安定化、合理化。
及時化生產系統及時化生產系統 3434
Single-Card Kanban System
K
A
N
B
A
N
P
art N
um
ber:
1234567Z
Location:
A
isle 5
B
in 47
Lot Q
uantity:
6
S
upplier:
W
S
83
C
ustom
er:
W
S
116
Each container must have a card
Assembly always withdraws from
fabrication (pull system)
Containers cannot be moved
without a kanban
Containers should contain the
same number of parts
Only good parts are passed along
Production should not exceed
authorization
及時化生產系統及時化生產系統 3535
看板(容器)數量之決定1
K=容器數量。
d=工作中心之計劃使用率(預期每日需求)
。
p=每箱容器零件之平均加工時間。
W=在生產過程中之平均等候時間，加上每
箱物料的搬運時間。
C=標準容器之零件容量。
X=政策變數。反應生產系統的效率(10%以
內)
及時化生產系統及時化生產系統 3636
看板(容器)數量之決定2
k=
在前置時間期間的平均需求+安全庫存
每箱內的單位數量
=
d(w+p)(1+x)
c
及時化生產系統及時化生產系統 3737
看板(容器)數量之決定3
where
N = number of kanbans or containers
d = average demand over some time period
L = lead time to replenish an order
S = safety stock
C = container size
No. of Kanbans =
average demand during lead time + safety stock
container size
N =
dL + S
C
及時化生產系統及時化生產系統 3838
容器數量決定—範例
某汽車零件公司生產4輪傳動車的方向盤及
暫停系統中的搖桿手臂組合。一般1箱零件
在製造週期中需要天的加工及天的
物料處理和等候時間。零件每日的需求為
2000個單位。管理部門認為搖桿手臂組合
的需求不確定，所以其安全庫存為需求量
的10%。
若每箱內各有22個零件，則應授權的箱子
數量為多少。
及時化生產系統及時化生產系統 3939
小批量 (Small-lot production) 的效益
降低在製品存貨
減少因品質發生問題時所產生的檢驗和重
加工成本
減少儲存空間
問題更容易顯現
增加生產彈性
易於進行作業平衡
及時化生產系統及時化生產系統 4040
Inventory Hides Problems
及時化生產系統及時化生產系統 4141
Lower Levels of Inventory
Expose Problems
及時化生產系統及時化生產系統 4242
Components of Lead Time
(前置時間的元素)
Processing time
Reduce number of items or improve
efficiency
Move time
Reduce distances, simplify
movements, standardize routings
Waiting time
Better scheduling, sufficient capacity
Setup time
Generally the biggest bottleneck
及時化生產系統及時化生產系統 4343
快速籌置 (Quick setups)
Single-digit setup
The goal of having a setup time of
less than 10 minutes.
快速換模又稱一分鐘換模術 (single-
minute exchange of dies, SMED)
及時化生產系統及時化生產系統 4444
快速籌置的實施步驟
1. 1. 將換模作業流程劃分外部整備作業與內部整備作將換模作業流程劃分外部整備作業與內部整備作
業。業。
2. 2. 儘可能把內部整備作業改變成外部整備作業。儘可能把內部整備作業改變成外部整備作業。
3. 3. 消除內部整備所需的調整作業。消除內部整備所需的調整作業。
4. 4. 外部整備作業的標準化。外部整備作業的標準化。
5. 5. 推動平行作業。推動平行作業。
6. 6. 利用機械提高換模效率。利用機械提高換模效率。
7. 7. 其他管理部門的充分配合。其他管理部門的充分配合。
及時化生產系統及時化生產系統 4545
Common Techniques for
Reducing Setup Time1
及時化生產系統及時化生產系統 4646
Common Techniques for
Reducing Setup Time2
及時化生產系統及時化生產系統 4747
Common Techniques for
Reducing Setup Time3
及時化生產系統及時化生產系統 4848
平準化生產 (Uniform Production)
Results from smoothing production
requirements
Kanban systems can handle +/- 10%
demand changes
The way to reduce variability in
production
Smooths demand across
planning horizon
Mixed-model assembly steadies
component production
及時化生產系統及時化生產系統 4949
平準化—範例1
The APP of TOYOTA: 4500 vehicles per
week.
Two full shifts, five days per week →
450 per shift (480 minutes)
Three models are produced: Camry (C),
Avalon (A), and Sienna (S).
200 Camry, 150 Avalons, and 100
Siennas per shift
Cycle time: 480/450= (min)
及時化生產系統及時化生產系統 5050
平準化—範例2
First
200 C’s 200 C’s → → 150 A’s 150 A’s → → 100S’s100S’s
High average cycle inventory levelHigh average cycle inventory level
Lumpy requirementsLumpy requirements
Second
4 C’s 4 C’s →→ 3 A’s 3 A’s →→ 2S’s 2S’s
The cycle =9()= (50 times per The cycle =9()= (50 times per
shift)shift)
及時化生產系統及時化生產系統 5151
平準化—範例3
Third
C C → → S S → → C C → → A A → → C C → → A A → → C C → → S S → → AA
The setup times must be very setup times must be very short.
Component requirements is steadyComponent requirements is steady
Capacity requirements are smoothedCapacity requirements are smoothed
及時化生產系統及時化生產系統 5252
Quality at the Source1
Jidoka (自働化)
在生產過程中自動偵測缺點
Andon (安童)
在每個工作站裝置燈號系統，以指示問
題及落後狀態。
Undercapacity scheduling allows for
planning, problem solving &
maintenance
及時化生產系統及時化生產系統 5353
Quality at the Source2
防呆裝置日文發音為POKAYOKE ，是指在模
具，工具，機器設備上設計防止錯誤(不良)發生
的裝置，一旦作業員做錯或需要作業上的警示
時，防呆裝置可以預防或使機器停下來，確保
不產生不良品。
目視管理系統 (visual control)： 係透過顯示板
之顯示得以快速且明顯地發現異常、浪費、故
障、斷料等現場不順暢之情形，而達到能速謀
對策的一種管理系統。
及時化生產系統及時化生產系統 5454
Visual Control
及時化生產系統及時化生產系統 5555
Visual Control
及時化生產系統及時化生產系統 5656
Visual Control
及時化生產系統及時化生產系統 5757
Kaizen (改善)
Continuous improvement
Requires total employment
involvement
Essence of JIT is willingness of
workers to
Spot quality problems
Halt production when necessary
Generate ideas for improvement
Analyze problems
Perform different functions
及時化生產系統及時化生產系統 5858
Total Productive
Maintenance (TPM)
Breakdown maintenance
Repairs to make failed machine
operational
Preventive maintenance
System of periodic inspection &
maintenance to keep machines operating
TPM combines preventive maintenance
& total quality concepts
及時化生產系統及時化生產系統 5959
TPM Requires Management to:
Design products that can be easily
produced on existing machines
Design machines for easier operation,
changeover, maintenance
Train & retrain workers to operate
machines
Purchase machines that maximize
productive potential
Design preventive maintenance plan
spanning life of machine
及時化生產系統及時化生產系統 6060
導入JIT的基礎—5S運動
定義 功能
整理 (seiri,
organization)
把東西分成必要與不必
要，將不必要的東西撤
走。
排除資源空間的浪費。
整頓 (seiton,
tidiness)
需要的東西排放整齊以
便取用。
排除尋找，縮短作業或產品
線切換、準備時間。
清掃 (seiso,
cleanliness)
把工作場所掃除清潔，
去除雜物及灰塵。
提升效率，排除隱藏的工業
災害與品質不良。
清潔
(seiketsu,
maintenance)
保持整理、整頓、清掃
所建立之成果。
確保作業安全，延長設備壽
命，提升產品品質。
修養
(shitsuke,
discipline)
對於規定的事項確實遵
守並養成習慣。
加強小團體之自主性活動。
及時化生產系統及時化生產系統 6161
Supplier Policies1
1. Locate near to the customer
2. Use small, side loaded trucks
and ship mixed loads
3. Consider establishing small
warehouses near to the
customer or consolidating
warehouses with other suppliers
及時化生產系統及時化生產系統 6262
Supplier Policies2
4. Use standardized containers
and make deliveries according
to a precise delivery schedule
5. Become a certified supplier and
accept payment at regular
intervals rather than upon
delivery
及時化生產系統及時化生產系統 6363
及時生產系統Ⅱ (JIT II)
供應商進入工廠，成為客戶採購部門的積
極成員，駐廠代表取代採購人員、銷售人
員，甚至物料規劃人員。
及時化生產系統及時化生產系統 6464
推行JIT之先決條件1
正確之銷售預測可有效縮短製造前置時間。
生產部門依訂單及長、短期預測，規劃生產
水準。
訂購零件與供應商密切合作。
供應商依公司之需求預測作長期生產規劃。
依需求變動及生產變動更新需求。
及時化生產系統及時化生產系統 6565
推行JIT之先決條件2
採購部門將設計變更及未來新零件的需求
告知供應商。
供應商調整其生產、運送計劃以滿足公司
之更新排程。
供應商將零件以少量多批方式送至公司。
進貨零件皆應有高品質而不需檢驗。
及時化生產系統及時化生產系統 6666
JIT系統的效益1
降低存貨水準
降低需求空間
改進生產品質
減少前置時間
增加生產彈性
及時化生產系統及時化生產系統 6767
JIT系統的效益2
使生產流程更為順暢
增加生產水準
工人參與解決問題
促進與協力廠商的良好關係
降低間接勞力的需求
及時化生產系統及時化生產系統 6868
JIT實行的議題1
組織考慮
JITJIT系統的員工成本系統的員工成本
Problem-solvingProblem-solving
Lost some autonomy (little or no safety stocks)Lost some autonomy (little or no safety stocks)
合作與信任合作與信任
Scheduling, expediting and improving Scheduling, expediting and improving
productivity → lower-level personnel productivity → lower-level personnel
薪資系統與員工分類薪資系統與員工分類
JIT vs. Production volumeJIT vs. Production volume
Management’s flexibility vs. UnionManagement’s flexibility vs. Union
及時化生產系統及時化生產系統 6969
實行的議題2
程序考慮
Cellular design → costlyCellular design → costly
存貨和排程
主生產排程穩定性主生產排程穩定性
生產整備生產整備
Small lot sizes vs. large number of setupsSmall lot sizes vs. large number of setups
採購與物流採購與物流
Small shipments of purchased items vs. Small shipments of purchased items vs.
geographic dispersion of suppliersgeographic dispersion of suppliers
