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#Just in time inventory windows#

Lean manufacturing refers to the process of eliminating waste in the production process by identifying what adds value and what doesn't add value. However, they are different concepts that work together. Lean manufacturing, the Kanban system, and JIT system are often confused as the same thing. JIT, also nicknamed Toyota production system, is a complete opposite from the Just-in-case strategy that involves a manufacturer stocking inventory just in case there is an unexpected peak in production demand from customers. The components required to manufacture the cars arrive just as they are needed. This system typically relies on long-standing contracts within the local supply chain to deliver the different parts it needs to assemble an automobile. Taiichi Ohno, the founder of automobile manufacturer Toyota, is credited as being the father of the JIT inventory management system. Just in Time (JIT) inventory management was first adopted and perfected in Japan in the early 1970s. What is the History of Just in Time Production? Small-lot (single unit) conveyance: Use a control system, such as a kanban (card) system (or other signaling system), to convey parts between work stations in small quantities (ideally, one unit at a time).“Tally boards” record and analyze causes of production stoppages and slowdowns to facilitate correcting them later. “JIT lights” indicate line slowdowns or stoppages. A quality at the source ( jidoka) program must be implemented to give workers the personal responsibility for the quality of the work they do, and the authority to stop production when something goes wrong. Require supplier quality assurance and implement a zero defects quality program: Errors leading to defective items must be eliminated, since there are no buffers of excess parts.Teams of competent, employees must have responsibility for their own work. Flexible Work Force: Workers should be trained to operate several machines, to perform maintenance tasks, and to perform quality inspections.

Preventive Maintenance: Use machine and worker idle time to maintain equipment and prevent breakdowns.

Delivery lead times can be reduced through close cooperation with suppliers, possibly inducing suppliers to locate closer to the factory.

Reduce Lead Times (production and delivery): Production lead times can be reduced by moving work stations closer together, applying group technology, and cellular manufacturing concepts, reducing queue length, and improving the coordination and cooperation between successive processes.

Close cooperation with suppliers is necessary to achieve reductions in order lot sizes for purchased items, since this will require more frequent deliveries.

Reduce Lot Sizes (manufacturing and purchase): Reducing setup times allows economical production of smaller lots.

This can be done through better planning, process redesign, and product redesign.

Reduce or Eliminate Setup Times: aim for single digit setup times (less than 10 minutes) or “one-touch” setup.

An end item‟s bill of materials is periodically exploded to calculate the usage quantities of the various components that were used to make the item, eliminating the need to collect detailed usage information on the shop floor. Also, permits the use of backflushing to manage inventory. Meet demand fluctuations through end-item inventory rather than through fluctuations in production level.

Also, establish a mixed model assembly to produce roughly the same mix of products each day, using a repeating sequence if several products are produced on the same line.

#Just in time inventory windows#

Establish freeze windows to prevent changes in the production plan for some period of time.

Stabilize and level the MPS with uniform plant loading (heijunka in Japanese): Create a uniform load on all work centers through constant daily production.

What are the Elements of Just in Time Production? Just in Time production, also known as lean production or stockless production, attempts to improve profits and return on investment by reducing inventory levels (increasing the inventory turnover rate), reducing variability, improving product quality, reducing production and delivery lead times, and reducing other costs (such as those associated with machine setup and equipment breakdown). Back to: OPERATIONS, LOGISTICS, & SUPPLY CHAIN MANAGEMENT How is the JIT Inventory System Used? Just in Time can also be defined as “a philosophy of manufacturing based on planned elimination of all waste and on continuous improvement of productivity”.