Learn how Just in Time can help your business!

Do you know anyone who doesn’t like having their wishes answered on the spot? I don’t. And answering requests exactly at the time they are made is the basic premise of Just In Time!

Without you realizing it, many companies that are in their day to day, whether food, clothing or any other, have adopted this famous type of production.

So what is this method? How did it come about? What are the characteristics of a Just In Time system? To have all your questions answered, just read this article until the end!

What is Just In Time?

Just in Time is a method of reorganization to leverage the production system and eliminate waste. It aims to reduce costs by supplying and producing the materials in the right quantity and locations, in addition to being the time the customer needs.

With this objective, the company uses the equipment, materials, facilities and also the human resource in a leanest way.

It is important to emphasize that to characterize as a JIT model, it is necessary to use the minimum of labor, equipment and raw materials. Kanban is the most appropriate tool to "pull production" from customer demand.

But what is this? It is the name given to the colored cards that are used to authorize the production and movement of all materials during the production process.

How did the Just In Time system come about?

The Just In Time system appeared in Japanese lands in the early 1950s, after the damage caused by World War II.

With this destruction, the country had to reformulate itself completely, from the most basic necessities, such as food and housing, as well as in the automobile sector.

But what was the system of automobile production until then? It was Fordism, the "mass" production. It was characterized mainly by a high production volume, high inventory level, and little variety of products.

And that's where the Toyota Motor Company kicked in! It implemented a model of production that went against what Fordism preached. A model that could coordinate production according to specific customer needs, that is, produce only what the customer wants and at the right time!

Ah cool, but what were the differentials of this system? With the thought of producing only what the customer requested and at the right time, this system reduced the level of inventory to the minimum, achieving a greater diversification of the products.

This revolutionary production system began, over the years, to be incorporated into other Japanese manufacturers, and brought significant results to them. And it did not stop there ....

After this success, the European and American companies decided gradually to implement this philosophy. With that, Just in Time managed to reach the 4 corners of the world.

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Is there any company that is 100% Just in Time?

You probably think the answer to this question is positive. You should think that Toyota - the precursor of this system - is 100% Just in Time. But you're wrong.

Toyota is the closest that comes to this model, but it does not reach it’s totality. With that, the answer to this question is: no! There is no company that 100% Just in Time.

But you can still ask me, "What about fast-foods? Don’t they deliver what the client wants, in the amount and at the time he desires? " Yes you are right. They are JIT, but they are not completely.

Fast-foods go far beyond that, you have to look at the system as a whole, not just the part of the customer's relationship with the collaborator. When you enter the company, you can see that the workforce is overloaded, the equipment is tight, the work environment is not very good.

In addition, there is a high stock of raw materials and semi-finished products. These characteristics make fast-foods not identified as a totally Just in Time system.

Just in Time Objectives

The main objectives of Just In Time are the reduction of costs and waste within an organization, through continuous improvement.

Japanese culture has a great impact on the method, employees are always looking to optimize processes, avoiding possible failures and maintaining the quality of the final product.

Through the methodology, problems in the production line are reduced in a reduced way, avoiding overproduction, reducing manufacturing and waiting time, non-conforming products and transportation expenses.

What are the advantages and disadvantages of Just in Time?

The main advantage of Just In Time is the reduction of inventories, as they demand space and people dedicated to controlling the products. This management brings costs with labor and usually presents bottlenecks, as the control must be meticulous.

Another advantage is the complete control of the manufacturing process, in this way it is possible to prevent errors from creeping in, causing significant problems. In addition, as the process is flexible, employees have more time to perform their functions with quality.

The disadvantages are related to the fact that Just In Time works well with companies that have a certain stability in terms of suppliers, in addition to good planning.

The company that intends to adopt the methodology has to know its processes and adopt a stock level according to its reality.

What are the characteristics of Just in Time?

There are many characteristics of this production system and in this article I will list and explain 9 of them. Are you ready? So let's go!

1. Machines sequenced according to the process

This way you can create a flow in your company. Facilitating the movement of materials, optimizing the process. What if the machines are not in the correct flow?

It will have to "go and return" constantly, generating movements unnecessary for the process, and consequently, not adding value.

2. Small and inexpensive equipaments

Flexible machines are required for the process, which do exactly what you need. You don’t need to have equipment with much higher capacity than you need.

But what if demand increases? In this situation it is important to make a projection of how much it will increase, and thus, according to it, increase the amount of machines and the way they produce.

For if it is not done that way, you will spend a lot on maintaining these equipments, generating unnecessary costs. After all, the less you spend, the better!

3. Single Part Flow

This feature is of utmost importance to the Just In Time system. Working with one piece at a time generates more specific work. This generates some benefits, but the main one is: do not create intermediate lots in the production process.

Eliminating one of the wastes, improving process as a whole, and adding value.

4. "U" cell; counter-clockwise

What’s the "U" cell? Make the layout of process machines in the form of the letter "U". So the ends of the lines are closer together.

The benefit of doing this is to generate a much closer communication between the collaborators, being able to help each other and share the activities. And why does it have to be counterclockwise?

The answer is simpler than you think! Most of the employees are right-handed, making it easier to work, which contributes to a more rapid and continuous work.

5. Multifunctional operators

They are called "chameleon" collaborators, that is, they adapt to any environment. This is very important because, just inside a cell, they can switch jobs.

If an operator can’t go to work, it is possible to replace him without very drastic losses and not compromising the process as a whole.

6. Standing workers, moving while working

Working sitting is much more comfortable, I know. But this in the future can be very detrimental to health, causing damage to the spine.

This way, you can improve the work environment, improving the process, the stations, and of course, the ergonomics of the collaborator.

7. Ergonomically Correct Operations

This feature is basically within the previous one. It aims to take out the chairs, raise the level of the tables at the height of the workers, so they can work properly.

No one deserves to be in pain. For this has to have these changes in the production environments, to avoid these problems with health.

8. Production guided by Takt Time 

No, I'm not speaking Greek. Actually, I'm speaking German. Takt means rhythm. With this, it is important for the process to work in pace, steadily. That is, there can be no interruptions during production.

For you to monitor if you are actually working in rhythm, correctly and meeting your client's needs, you can create a visual table, called "hour-hour table".

This way you can see how many pieces you produced in an hour and if you meet the expectations of production.

9. Standard Operations: defined and implemented

We have arrived at the last characteristic. It is intended that each worker has to perform their jobs in a standard way, already established. All of them are previously trained to do their jobs according to this standard process.

With everyone following in a harmonious way this standard process, the activities will be carried out with greater speed and also with a superior quality.

How to implement Just in Time?

The implementation of Just in Time is the most important step and for this implementation to be successful it is necessary to follow some steps that will be shown below.

1- Organize your goals

Realigning your company's goals is part of the Just in Time implementation process. Objectives are a reflection of where your company intends to be in a given period of time.

2-Realign the metrics

It is important to define KPIs so that all sectors must return around a main objective, always seeking to contribute to achieving the defined metrics.

3- Investment in training

The way in which changes occur within a company needs to be conveyed clearly and objectively, preventing any errors arising from lack of communication from happening.

In addition, it is important to provide employees with periodic training to adapt to the new management model implemented.

4-Rethink spaces

The physical structure of the company is very important when implementing Just In Time, it is important to map the internal processes, such as equipment routes and workflow. Everything must be organized as well as possible.

"In every crisis, there is an opportunity!"

The story of the Just in Time production system faithfully shows the veracity of this saying. After a tragic event that marked the history of the world, Japan was able to rebound in a meteoric way.

This restructuring took place with the change of the production process, and this same process, improved the system of production of several companies of the country, and spread to the world.

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