JIT Just in time management: optimizing operations
Working JIT or “just in time,” as it’s often referred to, is the industrial philosophy that can be summarized as manufacturing strictly necessary products, at the precise moment, and in the proper quantities. This implies purchasing or producing only what is needed and when it is needed.
What is JIT?
The just in time philosophy consists of a series of principles aligned with Lean Manufacturing, allowing us to adapt our production systems to demand, offering a wide variety of products, increasing models, and quantities. This way, we can not only reduce our costs and delivery time but also take advantage of market niches.
Next, we will see what the fundamentals of this methodology, widely used in industrial engineering solutions for supply chains and Quality Management systems, are.
What are the fundamental principles of JIT?
In addition to the need for internal cultural change to assimilate these new concepts, the correct implementation of JIT requires the following aspects.
1. Just in time requires resource flexibility
This implies having versatile workers capable of assuming various tasks, multi-use machinery that adapts to different needs, and a plant layout that groups operations by process. Resource versatility is essential to respond agilely to fluctuations in demand and ensure efficient and timely production.
2. Operating with a PULL system is another requirement of JIT
One of the cornerstones of Just In Time is operating under a PULL system, an essential aspect of JIT philosophy. This means that the traditional PUSH system, where a station or activity pushes products or information to the next process regardless of its actual need, should be avoided. Instead, under the PULL system, products or information are “pulled” or “required” from the next workstation based on actual demand.
This approach ensures more agile and efficient production since only what is needed is produced at the right time, avoiding waste of resources and unnecessary inventory accumulation. Thus, a more agile and market-responsive supply chain is achieved. Successful implementation of the PULL system is a crucial step to fully capitalize on the benefits of Just In Time in production management. For more information on this topic, we recommend reading this article on operational processes.
3. Having measured, analyzed, and controlled critical process times.
The critical times of the process include key moments such as machine setup time, processing time, and waiting times. By measuring these intervals, areas of inefficiency and bottlenecks that hinder production are identified.
Analyzing these times allows for the discovery of improvement opportunities. For instance, if setup time is lengthy, quick tool change techniques can be implemented. Similarly, if there are prolonged waiting times, activities can be rearranged to optimize workflow.
Controlling these times involves implementing systems and procedures to keep them within acceptable limits. This may entail staff training in continuous improvement techniques or the implementation of real-time monitoring systems.
In summary, managing the critical times of the process is essential for JIT success. By measuring, analyzing, and controlling these times, companies can enhance efficiency, reduce costs, and effectively meet customer demands, thereby maintaining competitiveness in the market.
4. JIT also implies minimizing invetory stocks
Inventory management focuses on streamlining and improving dynamics with our suppliers and subcontractors. In the context of Just in Time, it’s essential to have precise management of critical process times. One of the key indicators deserving special attention is the “Lead Time,” which represents the time elapsed from when a customer places an order until they receive the requested product. Measuring, analyzing, and controlling this Lead Time is essential for optimizing operational efficiency.
By having a deep understanding of critical times, companies can identify bottlenecks and areas for improvement in their supply chain. This enables them to reduce delivery times, offer shorter lead times, and enhance customer satisfaction. Additionally, by reducing Lead Time, the need for maintaining large inventories is diminished, aligning perfectly with the JIT principle of eliminating waste and maintaining minimal inventory levels.
5. Having zero tolerance for errors
Zero tolerance for errors is a cornerstone in the philosophy of Just in Time. In this approach, Quality Management takes priority, and it’s expected that each product meets committed quality standards. This means avoiding the production of products if quality cannot be guaranteed.
Zero tolerance for errors is based on the premise that it’s more efficient and cost-effective to prevent errors than to correct them later. By producing with quality from the outset, the likelihood of resource waste in rejection or rework is reduced. This not only saves time and money but also improves customer satisfaction by providing reliable and high-quality products.
The culture of zero tolerance for errors involves meticulous attention to processes, ongoing employee training, and the implementation of effective quality control systems. Ultimately, this approach contributes to operational excellence, cost reduction, and competitiveness in the market.
6. Adopting the 5S methodology
The 5S methodology is an essential component in the implementation of Just in Time. It consists of five Japanese principles: Seiri (Sort), Seiton (Set in Order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain). These principles are applied to create a safer, more organized, and cleaner work environment.
The 5S methodology, by creating a clean and organized environment, significantly contributes to efficiency and Quality Management in production, while also improving workplace safety and fostering a culture of continuous improvement.
7. Having implemented a SMED system
The implementation of a SMED system, which stands for “Single-Minute Exchange of Die,” or “Tool Change in Minutes,” is essential in the Just in Time strategy. This system focuses on reducing the time needed to change a machine or production process from one product type to another, enabling greater flexibility and agility in production.
A quick and efficient change of model is vital for adapting to demand variability, and the SMED system seeks to achieve this through various steps:
Identification of internal and external activities: Distinguishing activities that can only be performed when the machine is stopped (internal) and those that can be carried out while the machine is still running (external).
Converting internal activities into external ones: The goal is to minimize internal activities, allowing the model change to be primarily performed while the machine is in operation.
Standardization of processes: Standardized procedures are established to reduce changeover time, including the preparation of tools and materials before the changeover.
Continuous improvement: continuous improvement is encouraged to further reduce changeover times.
Successful implementation of the SMED system enables companies to quickly adapt to changing market demands, reduce waste of time and resources, and ultimately increase production efficiency, a central goal in the Just in Time philosophy.
8. Having implemented Total Productive Maintenance (TPM).
The implementation of Total Productive Maintenance (TPM) is essential in the Just in Time philosophy. TPM focuses on ensuring that machines and equipment are maintained in optimal operating conditions, which in turn contributes to efficient production and reduced downtime.
One of the main characteristics of TPM is the promotion of autonomous maintenance. This involves empowering production staff to be responsible for monitoring and caring for the machines they use. Each operator becomes part of the maintenance team, performing prevention, inspection, and minor repairs.
TPM also promotes a culture of continuous improvement by focusing on identifying and eliminating sources of inefficiency and downtime in equipment. This helps reduce unexpected breakdowns, unplanned downtime, and ensures that machines operate optimally.
How is JIT applied?
Just In Time is a management methodology that focuses on eliminating waste and increasing efficiency in production. Its main objective is to deliver the right quantity of products at the right time, minimizing inventories, and reducing costs. To apply JIT:
Precise planning: It begins with thorough planning of production and demand. This involves identifying how many products are needed and when they are needed.
Inventory reduction: JIT advocates for maintaining minimal inventory levels. This forces companies to produce only what is required, reducing storage costs and minimizing the risk of obsolescence.
Flexible production: Production must be agile and capable of quickly changing to adapt to demand fluctuations. Small batch production is a key feature of JIT.
Constant quality: Quality control is essential. Detecting and correcting quality issues early prevents loss of time and resources.
How does Just in Time (JIT) influence customer service?
JIT has a significant impact on customer service. By producing and delivering products at the right moment, companies can effectively meet the needs of their customers:
Delivery lead time reduction: With efficient production and delivery, companies can offer shorter delivery times, increasing customer satisfaction.
Fewer defective products: By focusing on Quality Management from the beginning, JIT reduces the likelihood of delivering defective products to customers.
Customization: Flexible production allows products to be tailored to specific customer needs, enhancing customer satisfaction.
Reduced costs: Eliminating unnecessary inventories allows companies to offer more competitive prices to customers.
What are the objectives of Just in Time?
The objectives of JIT are clear and oriented towards continuous improvement:
Eliminate waste: One of the main objectives is to reduce waste at all stages of the production process, including time, raw materials, and space.
Improvement of efficiency: JIT aims to increase operational efficiency by minimizing downtime and optimizing available resources.
Quality improvement: Production under JIT is based on maintaining high-quality standards at every stage of the process.
Cost reduction: By eliminating excess inventory and improving efficiency, companies can reduce production costs.
How to achieve Just in Time production?
To achieve Just in Time production effectively, it is essential to:
Training and awareness: Train employees on JIT principles and create a culture of continuous improvement.
Automation and technology: Use information systems and technology to monitor and control production flow.
Collaboration with suppliers: Work closely with suppliers to ensure timely delivery of raw materials and components.
Continuous evaluation: Constantly track processes and results to identify areas for improvement and make adjustments.
In conclusion, Just In Time is a management philosophy that has transformed the way companies produce, deliver products, and provide customer service. By eliminating waste and improving efficiency, JIT not only reduces costs but also enhances customer satisfaction and increases competitiveness. Successfully applying JIT requires commitment, training, and a constant focus on continuous improvement.
