Just-In-Time Manufacturing-5 Principles

Introduction to Just-In-Time Manufacturing

Modern manufacturing is marked by efficiency and adaptability. A great way to incorporate these in the production flow is Just-In-Time Manufacturing. So, what is it? Here, in this blog, we shall understand what just-in-time means and what problem it solves. JIT is a an inventory management system. It involves procuring raw materials from suppliers directly with the production schedule of the manufacturing unit. Hence, the production company would receive supplies as and when needed. Of course, it involves a well-calculated demand forecast. 

Please Note- The following article is not an academic paper. We recommended not to cite it as a reference in any academic piece. 

5 Principles of JIT Manufacturing 

From the beginning of the production line till the delivery of produce, all are covered in just-in-time manufacturing. It helps to make the processes easy, makes sure that all the materials are provided as scheduled and the goods are delivered to the customers on the scheduled dates, ensuring customer satisfaction and demand. 

For instance, a business that creates customized furniture will not begin product assembly until after a customer order is received. The producer will find the right supplies to finish a product quickly. Just-in-time manufacturing aims to minimize wasteful spending and the need for extra storage space by only producing goods in response to requests. 

The five zeros are the guiding principles of Just-In-Time Manufacturing: 

1. Zero Stock

The goal is to prevent manufacturing products without any outstanding orders from customers. Producing extra goods that are not really needed is not worth the money and does not create value. 

2. Zero Delay

The production process should be fast and successful at every stage. This includes not having to wait a long time for supplies to reach the production facility or for workers to finish distribution and assembly. 

3. Zero Failure

The goal is to make every machine work well without any issues or delays. Manufacturers can achieve this by regularly checking and maintaining the machines to stop problems before they happen. 

4. Zero Defects

To avoid fixing the issues, returns of products from the customers, and hurting the organization’s reputation and name. Part issues in the production line should be eliminated completely, if possible. 

5. Zero Paper

Efficiency is increased, and waste is decreased by automating data collection and manufacturing operations. 

Did you know? Developed and popularized by Toyota in the 1970s, JIT has become a cornerstone of lean manufacturing practices globally.

Benefits of Just-in-Time Manufacturing 

Strategic usage of Just-in-Time manufacturing can result in several advantages by producing things that customers desire and require. A few of its benefits are: 

1. Better quality control

To reduce errors and improve product quality, this technique places a strong emphasis on the necessity of efficient quality control throughout the assembly line. 

2. Decreased inventory costs

This approach helps reduce inventory, meaning less products must be produced and stored. This lowers the storage costs. 

 

3. Flexibility to customer demand

If orders, delivery dates and production schedules are changed an organization can quickly adjust their production levels. This can help in meeting the customer demands. 

4. Enhanced production process efficiency

If organizations use this strategy, their workers can be continuously encouraged to work harder to improve efficiency and optimize their working routines. This can lead to more productive workstations with quicker production time. 

Other benefits include waste elimination, and minimum set up time.

Downside to Just-In-Time Manufacturing

Even though Just-in-Time manufacturing can improve the supply chain and assembly line and offer many benefits. This strategy still has some disadvantages. These include: 

1. Greater supply chain risk

The first is that it can cause delays. For example, there are issues in the supply chain such as suppliers have not given products on time, equipment is failing, or there are faulty parts being produced, all these can lead to delays. While just-in-time manufacturing needs a reliable and efficient supply chain where everything goes as planned and the products are delivered on time. 

2. More coordination and planning

This strategy also needs coordination and planning. In simple words, to implement just-in-time manufacturing you must carefully prepare everything and must have efficient teamwork among your suppliers. You must also make sure that all parts and equipment are available as scheduled. This can create issues as you might need more resources and may have to change your management strategy completely so that everything runs smoothly. 

3. Higher production costs

Since everything must be ideal in just-in-time manufacturing, you might have to order and deliver products more frequently. This can increase distribution and transportation costs, which are not beneficial. 

Implementing Just-in-Time Manufacturing 

To implement all the five zeros in your organization as discussed previously, you need careful planning and efficient coordination in your manufacturing practices so you can use just-in-time manufacturing. Read below on how you can apply this strategy to your assembly line processes:

Step 1: Evaluate current production process 

The first thing you need to do is to analyze your current manufacturing strategy to identify possible areas that can be further optimized. This might include improving quality control, reducing waste, or simplifying procedures. 

Step 2: Identify important suppliers 

Then you must determine which suppliers are required to keep the supply chain reliable and effective. You should check and verify whether the selected suppliers can provide the items on time or not. 

Step 3: Create a production plan 

It is important to produce an effective assembly line plan that shows all the supplies and techniques needed at each level of the production process. Moreover, a delivery timetable must also be produced and included for each product. 

Step 4: Develop a communication system 

Build a strategy to contact suppliers so you can inform them about any modifications that are being made to the specifications of the product or the manufacturing schedule. This helps in guaranteeing timely and accurate delivery of raw materials in the appropriate quantities. 

Step 5: Train workers 

Workers should get training in Just-In-Time manufacturing techniques so they can use them on the shop floor. It is critical to give them the instruments and materials they require to finish tasks correctly the first time. For example, digital work instructions can be provided for efficient workflow. 

Step 6: Apply quality control protocols 

Implement quality control procedures in all your assembly line operations to ensure the finished goods meet all regulatory requirements. 

Step 7: Monitor and adjust processes 

Keep an eye on how effectively procedures are being followed so you can make any necessary adjustments. 

Conclusion

Dropslab can help you with managing tasks and implementing just-in-time manufacturing. Our software helps in simplifying the processes so that you don’t have to worry about facing preventable issues and defects. Everything is recorded in real time and any change in the supply chain can easily be updated and delivered to workers connected through our software- book a demo now.

FAQs

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