How do you achieve just-in-time production?

1 Assess your current situation

Before you can implement JIT, you need to understand your current production system and identify the sources of waste, inefficiency, and variability. You can use tools such as value stream mapping, 5S, and Kaizen to analyze your workflow, layout, inventory, quality, and customer needs. You should also benchmark your performance against your competitors and industry standards to set realistic and measurable goals for improvement.

2 Build relationships with suppliers

One of the key elements of JIT is to reduce inventory levels and avoid overproduction by ordering only what you need, when you need it, and in the exact quantity you need. This means you need to have reliable and flexible suppliers who can deliver high-quality materials and components on time and at a reasonable cost. You should establish long-term partnerships with your suppliers and communicate frequently and clearly about your production plans, schedules, and expectations. You should also seek to consolidate your supplier base and reduce the number of deliveries and transactions.

3 Optimize your production process

Another essential aspect of JIT is to streamline your production process and eliminate any non-value-added activities, such as waiting, moving, storing, inspecting, and reworking. You can use techniques such as cellular manufacturing, single-piece flow, pull systems, Kanban, and Poka-yoke to design a smooth and continuous flow of work that responds to customer demand. You should also empower your workers to make decisions, solve problems, and suggest improvements on the shop floor.

4 Implement total quality management

Quality is a crucial factor for JIT, as any defect or error can disrupt the production flow and cause customer dissatisfaction. You should implement total quality management (TQM) practices, such as quality at the source, statistical process control, Six Sigma, and continuous improvement, to ensure that your products meet or exceed customer expectations. You should also involve your suppliers and customers in your quality efforts and seek feedback and suggestions for improvement.

5 Adopt a flexible and lean mindset

JIT is not only a set of tools and techniques, but also a philosophy and a culture that requires a flexible and lean mindset. You should be willing to adapt to changing customer needs and market conditions, and to embrace change and innovation. You should also foster a culture of teamwork, collaboration, and learning among your employees, suppliers, and customers. You should reward and recognize your staff for their contributions and achievements, and provide them with training and development opportunities.

6 Monitor and evaluate your results

The final step of achieving JIT is to monitor and evaluate your results and compare them with your goals and benchmarks. You should use key performance indicators (KPIs), such as inventory turnover, cycle time, lead time, customer satisfaction, and profitability, to measure your progress and identify any gaps or opportunities for improvement. You should also review your processes and practices regularly and make adjustments as needed to sustain and enhance your JIT performance.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?