What is Just-In-Time Manufacturing?

Just-in-time (JIT) manufacturing is a Japanese workflow methodology that strives to decrease flow times in production and cut down on waste. It involves working closely with suppliers, manufacturers, and distributors to ensure that products are delivered on time and without errors.

Ultimately, JIT requires a responsive and flexible supply chain that adjusts to changes in product demand and production criteria. It was first introduced by Toyota in the 1970s and has since become a widely adopted strategy used by manufacturing industries around the globe.

JIT manufacturing has been credited with boosting product quality, decreasing costs, and enhancing customer satisfaction by distributing goods quickly and efficiently.

The strategy is very similar to lean manufacturing, the process of minimizing waste while maximizing productivity — and the two terms are usually used interchangeably.

Read on to learn more about the inner workings of JIT and how to implement it on the shop floor:

5 principles of JIT manufacturing
Benefits and disadvantages of just-in time manufacturing
Implementing JIT manufacturing

5 principles of JIT manufacturing

JIT helps create a smooth, continuous flow of products that are made to meet customer demand, from assembly to delivery.

For example, a company that manufactures custom-made furniture will wait to start assembling products until a customer order is received. The manufacturer will source the proper materials to complete a product within a short time. The goal of JIT is to create products only when orders arrive to avoid the unnecessary costs and storage space for excess inventory.

JIT consists of five principles called the five zeros:

Zero stock: The objective is to avoid producing goods that have no pending customer orders. Creating a surplus of products is unprofitable and doesn’t add value.
Zero delay: Every step in the production process should be quick and efficient. This means not waiting an extended period of time for materials to arrive to the manufacturing plant or on workers to complete assembly and distribution.
Zero failure: It’s expected that all machines will run reliably without any delays or breakdowns. To accomplish this, manufacturers can implement preventive maintenance with regular inspections to avoid unexpected issues.
Zero defects: The goal is to reduce part defects (to zero if possible) in order to avoid corrective processing, customer returns, and damage to a company’s reputation.
Zero paper: Automating production processes and data collection increases efficiency and reduces waste.

Benefits and disadvantages of just-in-time manufacturing

JIT manufacturing can yield a number of benefits when used strategically to create goods that customers want and need.

Some of its advantages are:

Better quality control: This methodology emphasizes the need for effective quality control throughout the assembly line to decrease deficiencies and boost product quality.
Decreased inventory costs: This strategy minimizes the need for creating and storing large amounts of inventory. In return, warehouse and inventory holding costs are reduced.
Flexibility to customer demand: This method gives manufacturers the flexibility to respond quickly to changes in customer demand (e.g., adjusting production levels and schedules to satisfy consumers).
Enhanced production process efficiency: This technique promotes continuous improvement and streamlining of processes that can lead to greater efficiency in the workplace.

Although JIT can significantly improve how and when products are made, it comes with some drawbacks, such as:

Greater supply chain risk: JIT necessitates a reliable and efficient supply chain to distribute products in a timely manner. Any disruptions in the supply chain (e.g., defective parts, supplier issues, machine breakdowns, and more) can result in delays in product distribution.
More coordination and planning: JIT requires thorough coordination and planning among suppliers to ensure that materials and parts are available when needed. This may involve extra resources and management attention to make sure all aspects of the production process are running smoothly.
Higher production costs: This technique may require more frequent ordering and delivering of materials, which can increase transportation and distribution costs.

Implementing JIT manufacturing

Applying JIT to everyday manufacturing processes requires careful planning and coordination to achieve the five zeros described in the above section. Read on to learn how to implement this approach in assembly line processes.

Step 1: Evaluate current production process

Start by assessing your current production process to pinpoint areas that can be improved. This may involve streamlining processes, decreasing waste, and boosting quality control.

Step 2: Identify important suppliers

Next, identify which suppliers are needed to maintain a reliable and efficient supply chain. Make sure that they can deliver parts in a timely manner.

Step 3: Create a production plan

It’s crucial to develop a detailed assembly line plan that describes the materials and procedures required during each stage of the manufacturing process. It’s also imperative to include a delivery schedule for each product.

Step 4: Develop a communication system

Set up a communication system with suppliers so that they know of any changes that are made to production schedules or product requirements. This helps with making sure that raw materials are delivered on time and in the right quantities.

Step 5: Train workers

Train workers on JIT manufacturing procedures so that they know how to implement them on the shop floor. It’s important to provide whatever tools and resources they need to complete tasks right the first time around.

Step 6: Apply quality control protocols

Apply quality control measures to all of your assembly line processes to confirm that final products meet all compliance standards.

Step 7: Monitor and adjust processes

Monitor how well procedures are being implemented so that you can adjust anything that isn’t working.

Augmentir is the first ever AI-powered connected worker solution that helps industrial companies reap the benefits of just-in-time manufacturing. Our software helps streamline processes so that you don’t have to worry about running into avoidable defects and problems.

Let us help you streamline your frontline operations to improve production quality though digitized work procedures. Get in touch with us for a free demo.