'Just-In-Time' for Implementing Lean Manufacturing Six Sigma

Just-In-Time (JIT) manufacturing is a concept frequently misunderstood. The name may imply materials and a workforce arriving at the last moment during manufacturing, but this is not the case. Instead, JIT involves controlling the flow of materials and manpower so that adequate resources are on hand when needed. It ensures an organization produces and delivers the right items, at the right time, in the right amounts, all of which are key in a lean manufacturing Six Sigma organization.

The overriding principle of JIT is that a cache of excess inventory and materials do not contribute to the improvement of an organization's profitability. In fact, this unnecessary reserve actually carries a financial and performance cost. In addition to occupying valuable space on the manufacturing floor, excess materials obstruct the efficient flow of work. In terms of labor, JIT techniques direct the workforce's efforts where they are needed, when they are needed. The system eliminates idle time and performance inefficiencies.

In an active JIT environment, workers are placed in areas where work is needed, and an adequate supply of materials is funneled in at a controlled rate. Inventory goes out the door to customers, rather than accumulating.

Goals of Just-In-Time

The JIT philosophy synchronizes well with the lean manufacturing Six Sigma implementation process. Both stress the elimination of waste and simplification of processes. Just-In-Time techniques strive to improve lead time and reduce the inventory on hand. Organizations are then freed to concentrate on producing and delivering products to meet consumer demand. In addition, the work environment is restructured to enable more efficient use of the workforce. With less idle time, workers efforts produce more, and quality improves.

Enacting Just-In-Time Manufacturing

Elements of a Just-In-Time system can be tailored to any manufacturing environment. These elements are all designed to effect both the flow of materials and workforce performance. Examples include:

  • layout redesign
  • batch reduction
  • parallel processing
  • pull manufacturing (kanban)
  • flow manufacturing
  • standard work

Whatever the method, JIT seeks to most efficiently align the demands of the marketplace with the organizational performance.

Importance of Just-In-Time in Lean Manufacturing Six Sigma

JIT can play an important role in implementing lean manufacturing Six Sigma principles. Through these techniques, it becomes possible to :

  • Distinguish between integrated processes and loosely connected functional pieces.
  • Understand and value the importance of integrating order management with material and capacity planning.
  • Note the manner in which information from order-to-delivery operations must be accessible at every level of the organization to achieve successful, profitable results.

JIT is an effective means by which lean manufacturing Six Sigma can flourish. Rather than a rush to gather materials and manpower, Just-In-Time principles enable organizations to meet customer requirements with the greatest efficiency and least amount of waste.