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Disadvantages of just in time
How lean approach is utilised in the production system
Lean production advantages and disadvantages of lean production
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Recommended: Disadvantages of just in time
This essay will critically evaluate the use of just in time strategy in the supply chain system by describing the method itself, then it will look for possibilities that it could benefit or harm the operations during crisis and unexpected events and its effect on the operations. This is followed by suggestions on how to survive in crisis events to companies who use lean supply chain system and tries to provide alternative approaches to this concept.
In today’s business world, companies are desperately trying to find a way to gain a competitive advantage and make more profit. One of the ways to do so is by reducing the cost of their productions. Operations have to make sure their production system is fast enough to meet the demand and the requirements
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Some companies need to have a confirmed order to start making a product due to its attached cost and materials. Some businesses need to have high stocks due to the high demand of a product and by doing this they have always have the product to sell to the customers on time. Finally, some businesses found a smart strategy to set their supply chain on it, which is the ‘Just in Time’ (JIT) supply system, a strategy based on eliminating the waste that is linked to time, labour and storage space, (Vijay and Sadikot, 2016). In this way, they have just enough supplies and inventory to meet the demand and they do not have high volume of finished products in their stock rooms, which drastically help them to be super-efficient in their production, be fast and have more cash in their hands. On the other hand, operations who source globally are highly sensitive with this system. Moreover, operations with low volume of production and high variability will definitely face problems with this …show more content…
2010). As it has been mentioned, this lean production system has been very successful and many other car makers are implementing this as their manufacturing and operational strategy. This is due to its basic objective which is reducing costs by eliminating the waste associated by time, labour and storage space. Many, believe that the success of the company widely relies on the production strategy of the company. As (Bortolotti et al. 2013) point out, “JIT improves most performance dimensions, in particular manufacturing costs, inventory turnover, cycle time, on-time delivery, fast delivery, volume flexibility and mix flexibility”. This shows that Just in time strategy can definitely improve the operational performance of businesses especially in high repetitive manufacturing systems and be used in order to remove the waste from the operation
In today’s marketplace and world of business it is critical that customers receive a quality product in a timely manner from the supplier. It is also critical as a supplier and business that waste is reduce in all categories including inventory, time, facility space, storage, and also transportation. Several methods have been created and adopted over the past 20 years from top companies with successful track records such as Toyota, GE, and Motorola. One method or process that has proving to be successful is none other than Lean Six Sigma. Lean Six Sigma evolved as a concept in the early years of the 2000s which combines the Lean manufacturing method and also the concept of Six Sigma. When you blend both processes together, you have in return a better delivery schedule, better quality, outstanding employees, satisfied customers and last but not least profit. Profitability as we all know is the goal for any business, organization, or manufacturing company as well as to increase throughput while reducing inventory and operational expense (Eliyahu M. Goldratt).
Some of the bottleneck foremen come up with methods of streamlining their processes to increase throughput at their stations. And for a time, things seem to be improving and inventories are slowly shrinking and more backlog orders are being filled. Then Stacey reveals a proble...
Based on future supplier contracts, shortening lead time for delivery of parts and materials establishing leaner processes, namely addressing wastes identified through implementing a Just-In-Time (JIT) system. A centralized wharehouse system, co-located near the manufacturing plant will reduce shipping and transportation costs or look for larger space with warehousing capacity. Savings, significant enough will be a factor if space with warehousing falls within the
Continuous improvement (CI) refers to a philosophy consisting of improvement activities that increase successes and reduce failures in a production process (Bhuiyan & Baghel 2005, p. 761). It involves activities and processes that focus on continuous and incremental innovation (Bessant et al., 1994, p.17). CI is a new approach that enhances productivity, performance, and achieves competitive advantage needed in the highly competitive industries. It may also serve as a complementary approach to other quality improvement initiatives such as total quality management (TQM) (Pike, Barnes, & Barnes 1995, p. 23; Larson 2003; Lassen, Gertsen, & Riis 2006; Oakland 2007, p. 227). The purpose of this research is to explore the application of production systems engineering methods in the CI at manufacturing plants.
middle of paper ... ... Reduce overhead costs of working with JIT based customers by. o Consider implementing JIT production and inventory methodology. o Reduce order handling overhead by implementing standing JIT orders (i.e. one order for a total quantity over time, instead of a separate order for each delivery).
The basic premise for JIT is fairly simple: a company only produces an item when there is a need, or just-in-time for a company or individual to purchase it (Manoocherhi, 1988). The theory of JIT also accepts that there may be a need for an item at another work station and this would also create the need for production. Rather than utilizing the common practice of mass production and attempting to sell and distribute the products after they are created, JIT waits until there is a defined need that must be met. By doing this, JIT systems allow companies to decrease the level of production, decrease the necessary manpower hours utilized in mass production modes of supply, and eliminates the waste inherent in over-production. These techniques are especially effective for small companies, who are far less able to absorb the impact of unsold products. JIT has been shown to significantly impact reductions in overhead costs that reduce re-investments, and encourage stabilizing business practices(Manoocherhi, 1988).
In the competitive environment, it is necessary for moving products involves reception of products at an intermediate location, store, repackage, clear customs and transport to final destination. The other factor in the supply chain logistics is speed given information flows fast in the internet era. The customer expects everything quick accustomed to the instant status access to the information. With the real time inventory, customer expects the location of the product, it is next scheduled movement and the final delivery schedule.
Inventory management is a method through, which a business handles tangible resources and materials to ensure availability of resources for use. It is a collection of interdisciplinary processes including a full circle from the demand forecasting, supply chain management, inventory control and reverse logistics. Inventory management is the optimization of inventories of manufactured goods, work in progress, and raw materials. According to Doucette (2001) inventory management can be challenging at times; however, the need for effective inventory management is largely seeing more as a necessity than a mere trend when customer satisfaction and service have become a prime reason for a business to stand apart from its competition. For example, Wal-Mart’s inventory management is one of the biggest contributors to the success of the company;
(The origin of the Toyota production system, n.d.). These ideals led to the Just-in-Time method, which is a practice of only making what is needed, when it is needed, using only the amount needed. Just-in-Time is incorporated within the continuous improvement method being that if all elements are performed efficiently and effectively, then it is evident that the corporation will have a lesser chance of becoming stagnant. Their ability to focus on research and development allows them to keep their technological advantage at bay amongst their products, which in turn leads to innovation and sales.
According to Srinidhi and Tayi (2004), companies that are flexible enough and are able to change from a JIT system to a traditional inventory system will have a competitive advantage over other firms who do not switch. In such uncontrollable environments, the major benefit of JIT becomes a handicap with the increase in delivery times and the added data handling and coordination required in such times. This leads to a decrease in quick response time, which ultimately leads to increase in costs to the firm.
Just In Time, Toyota Production, and Lean Manufacturing are productions systems intended to reduce costs, and waste associated with inventory and manufacturing.
In 1950s, Toyota has developed lean thinking. The Toyota Production System aspires to minimize waste and increase efficiency while at the same time enhances its product quality. From this initiative, Toyota managed to widen its competitive edge by employed fewer employees in the car production with a small number of flaw products.
This is the activity carried out by organizations that own production sites, and their performance has a major impact on product cost, quality, speed of delivery and delivery reliability, and flexibility [8]. As it is quite an important part of the supply chain, production needs to be measured and continuously improved. Suitable metrics for the production level are as follows. Order lead-time, the total order cycle time, called order to delivery cycle time, refers to the time elapsed in between the receipt of customer order until the delivery of finished goods to the customer. The reduction in order cycle time leads to reduction in supply chain response time, and as such is an important performance measure and source of competitive advantage [9]. It directly interacts with customer service in determining competitiveness. Range of product and services: According to [8] a plant that manufactures a broad product range is likely to introduce new products more slowly than plants with a narrow product range. Plants that can manufacture a wide range of products are likely to perform less well in the areas of value added per employee, speed and delivery reliability. This clearly suggests that product range affects supply chain performance. Effectiveness of scheduling techniques is another important measure of supply chain effectiveness. Scheduling refers to the time or date on or by which
Toyota has implemented many different systems such as performance monitoring software, the Just in time (JIT) inventory system, electronic quality control system, communication system and information system thought out their value chain which enable to make correct decision during the manufacturing process. They have identified that having large inventories of spares cost them extensive capital and they have implemented the Just in time (JIT) inventory system which advices the suppliers the exact spares that the product line required and provides a time frame. Toyota adopted continuous learning and embraces change allowing their staff to research and innovation (Toyota
Inventory management involves planning, coordinating, and controlling the acquisition, storage, handling, movement, distribution, and possible sale of raw materials, component parts and subassemblies, supplies and tools, replacement parts, and other assets that are needed to meet customer wants and needs (Collier & Evans, 2009). In order for business and supply chains to run smoothly, they must meet all the listed requirements for effective inventory management. Thus, inventory management must be managed wisely in order to be a successful an...