How JIS Manufacturing Eliminates Part Hunting and Boosts Assembly Speed ?

Just-in-Sequence (JIS) manufacturing tackles the hidden enemy of assembly lines: wasted time spent searching for parts. Here's how JIS streamlines the process and leads to faster assembly times:

The Hidden Enemy of Assembly Lines: Part-Hunting Chaos

Traditional production methods can harbour a hidden enemy that significantly slows down assembly lines: part-hunting chaos. This occurs when workers spend a considerable amount of time searching for the components they need to build a product. Here's a breakdown of the problem and its consequences:

The Disruption Cycle:

1. Shifting Focus : When a worker needs a specific part, they have to stop the assembly process. Their focus shifts from actively building the product to finding the missing piece. This mental break disrupts their workflow and momentum.
2. The Search Begins : The hunt for the part can involve:

• Consulting manuals: Workers might need to refer to parts lists or diagrams to identify the correct component.
• Checking storage bins : Sorting through bins or shelves filled with various parts can be time-consuming and frustrating, especially if the organisation is poor.
• Walking to a central location : In some cases, parts might be stored in a central warehouse, requiring the worker to walk away from their station, further disrupting the workflow.

3. Identification Risk: With multiple similar components, there's a chance of grabbing the wrong one. This can lead to :

Rework: If an incorrect part is used during assembly, it might need to be disassembled and replaced with the correct one , adding significant time and potentially damaging the product.

Delays: Identifying and rectifying mistakes takes time, further delaying the assembly process.

This seems to be a minor problem but when it comes to a manufacturing plant where the production quantity is huge, this disrupts the flow and reduces the productivity of the production unit which in turn increases the production cost per unit. In a competitive market companies cannot afford this cost.

The JIS solution : Transforming Chaos into Clockwise Precision

Just-in-sequence (JIS) manufacturing directly addresses the problem of part-hunting chaos with a series of clever solutions:

1. Pre-sequenced Kits: Imagine a well-organized toolbox specifically designed for a particular task. In JIS, parts for a specific product (like a car door) arrive pre-sorted in the exact order they'll be used for assembly. These kits can be:

• Modular containers: Trays or bins compartmentalized to hold each part needed at a specific stage of assembly.
• Labelled bags: Individual bags clearly labelled with the part name and assembly step, ensuring no confusion.
• Kanban systems: A visual inventory management system where parts are stored on labelled racks or shelves, indicating the exact quantity needed for each assembly stage.

2. Delivery at the Point of Use: Gone are the days of workers trekking to a central location to find parts. With JIS, the pre-sequenced kits are delivered directly to the workstation where they'll be used. This eliminates:

• Wasted walking time: Workers can focus on assembly tasks without interruptions caused by searching for parts in distant locations.
• Inventory confusion: Having parts readily available at the workstation minimizes the risk of grabbing components from the wrong project or bin.

3. Visual Cues for Seamless Assembly: JIS incorporates visual aids to further streamline the process and minimize errors:

• Clearly labelled bins: Each bin or container holding parts is clearly labelled with the part name or identification code, ensuring workers can easily identify what's inside.
• Assembly sequence indicators: The kits themselves or the workstation might have visual cues like numbers or even lights that illuminate the next part to be used, guiding the worker through the assembly process.
• Color-coded systems: Some JIS implementations use color-coded parts, bins, or labels to create an intuitive assembly flow, especially helpful for complex products.

In essence, JIS transforms the chaotic world of part-hunting into a precisely timed and visually guided assembly process. This not only improves efficiency but also creates a smoother workflow for workers, ultimately leading to a more streamlined and productive manufacturing environment.