As opposed to just-in-time, the just-in-case philosophy encourages you to have a sufficient stockpile of materials, components, and finished products in your inventory. This ensures that there are always sufficient materials and components for your assembly line. The first phase of any production process is to get the materials & components needed to make a product. And most likely, these materials & components are sourced from outside your plant. Thus, the delivery and storage of materials & components that need to be handled.

Combining Pull Systems with Continuous Flow

By dividing the total cost of goods sold (COGS) by the average inventory over a given period, the inventory turnover ratio reflects the number of times the company has sold its total average inventory. A company with little to no inventory has a much higher ratio than a company with equivalent COGS expenses that utilizes a more anticipatory production strategy. The just-in-time (JIT) inventory system minimizes inventory and increases efficiency.

Waste includes excess inventory, unnecessary processing steps, waiting time, defects, and excess motion. Just in Time production, often abbreviated as JIT, is a manufacturing philosophy that aims what production system is preferred by just in time to produce goods only when they are needed, in the quantities required, and in the exact order needed. The idea behind JIT is to eliminate waste in the production process, reduce inventory, and increase efficiency. You can prevent defects using our state-of-the-art product ordering system in our Quality Management module.

1. The just-in-time approach warrants meticulous planning and aligned efforts end-to-end, however.
2. Upon his return to Japan, he developed the Toyota Production System (TPS) – often regarded as the precursor of the modern lean manufacturing movement.
3. With these two concepts working together, you can effectively design a process for maximum flow.

Just in Time production is a strategy that has revolutionized the manufacturing industry, allowing companies to significantly improve efficiency and reduce costs. In this article, we will explore the concept of Just in Time production, its principles, benefits, and implementation steps. Be sure to check out other success stories where Azumuta’s modules have drastically improved our clients’ production efficiency. Look no further; Azumuta has the most comprehensive lean manufacturing software tools available in the market.

Continuous Improvement

Under the just-in-time production philosophy, unwanted variations are a threat, as they can lead to defects. In the following sections of this article, we will explain the techniques commonly used to implement the just-in-time production system. The “Just-in-Time” Production System is a popular jargon among lean manufacturing practitioners. It can deliver razor-sharp cost-cutting benefits that no other system could match. Yet, it’s also an incredibly challenging system to follow – and highly risky”. Inventory oversight streamlines thanks to pull-centric creation and techniques like Heijunka leveling production pace too.

In terms of JIT, smaller lots mean you’re only using what you need and nothing has to be stocked. Without clear channels of communication between departments, work will never proceed as efficiently as possible. Poor communication impacts production slows it down, creates inaccuracies in data and reduces profitability. Therefore, customer orders need to reach the planning department when sales inputs the order, which means you need one source of truth that informs all departments of your company at the same time. For just-in-time manufacturing to work, manufacturers must have a suitable product or service, a specific quantity and an agreed-upon timeframe. If you’re looking to implement a JIT manufacturing process, follow these steps.

Increased Efficiency and Productivity

This ensures your assembly line remains fully operational, even when faced with supply chain disruptions. In the final section of this article, we will also provide you with a freely downloadable lean manufacturing e-book PDF. With it, you can immediately start your plant’s transition to the just-in-time production system and become an all-around lean manufacturer.

For example, if a changeover takes 60 minutes, instead of doing a batch of 60 widgets, the financials look better when doing a larger batch… let’s say 3,600. Now, instead of wasting 1 minute per widget doing a changeover, it is reduced to 1 second per widget. The common management and accounting workaround is to increase the batch size. Takt time becomes obviously important when considering the design and management of a work cell. But as the batch size is reduced to an ideal size of one, some extraordinary things happen. Just in time is primarily the invention and success of Taiichi Ohno, who implemented the first concepts in 1949 and 1950.

Nonetheless, it’s essential to balance supplier competitiveness and supply chain security. Furthermore, always order materials & components in a quantity that matches the needs to fulfill your customers’ orders. If you order too few, you will have shortages that will disrupt your production process. As previously mentioned, the just-in-time production system follows the pull system method. This means that all parts of the production process, including sourcing materials and components, will only start once there’s a customer order. Moreover, storage space is unnecessary since a finished product will be immediately sent to the customer.

Traceability and compliance are non-negotiable in today’s manufacturing landscape, especially in JIT environments where each part’s history is essential for quality control. Next Plus provides integrated traceability & electronic records, ensuring that compliance is built into every stage of production. For decision-makers, Next Plus’ detailed analytics and reporting translates to a comprehensive view of the manufacturing process, empowering leaders with data-driven insights to refine JIT strategies further. Identify areas of waste, such as overproduction, excess inventory, or unbalanced workforce utilization. Understanding the initial state is crucial to making targeted improvements. One of the core principles of JIT production is the elimination of waste in all its forms.

By focusing on quality at every step of the production process, JIT helps companies deliver products that meet or exceed customer expectations. Companies that practice JIT production recognize that employees are a valuable asset and that their knowledge and skills are essential for achieving operational excellence. They invest in training programs to ensure that team members have the necessary skills to perform their tasks efficiently and effectively.

ProjectManager is project management software equipped with the right tools for JIT manufacturing. You can use ProjectManager’s kanban boards to create automated workflows and set task approvals, map out production plans on Gantt charts and track progress with real-time dashboards. Lastly, JIT production encourages the use of visual management techniques, such as Kanban boards and Andon systems. These tools provide real-time information about the production status, allowing for immediate detection and resolution of quality issues.

Begin your free trial today, elevate your manufacturing process, and minimize waste with increased efficiency. Moreover, you can create an individual performance report for each employee. This automatically-generated report contains abundant information, ranging from their skill levels to their training history. Ensure that your employees’ skills are always up to date with our Skill Matrix & Training module. With this module, you can effortlessly plan short and long-term training programs, attach training materials, select participating employees, and send automated reminders for your employees. In addition, ensure that everything is on track by capturing real-time pictures and videos from the shop floor.

Similar to other philosophies like Kaizen, Jidoka and Heijunka,  the just-in-time production system has its roots in lean manufacturing and Toyota. However, there are also lean manufacturing philosophies that originated from outside Toyota, such as First Time Right. Manufacturers must have reliable suppliers, skilled workers, and quality management systems in place.