Question

Describe the JIT implementation process. Why should some things be changed before others?

Answer 1

JIT building blocks:

1. Manufacturing Planning and Control

2. Product Design

3. Process Design

4. Human Resource/Organization Management

JIT implementation process (stepwise): 1 --> 2 --> 3 --> 4 --> 5 --> 6 --> 7 ---> 8 --> 9 --> 10

1. Design Flow Process - Here, we need to review the JIT building blocks. Review and align the Manufacturing Planning and Control operations. Reduce the setup time. Take on preventive maintenance. Check Flow Layout.

2. Total Quality Control - Here, we need to define worker role and responsibilities. Inspection processes need to be automated. SQC measures need to be defined.

3. Baseline and Stabilise Schedule - We need to level the schedules and establish time fences for MRP (frozen and liquid).

4. Demand/ Kanban Pull - We need to define and implement Kanban rules, check lot size policies, etc.

5. Work and Build Trust With Vendors - Review vendors list and categorise them, check their lead times and set metrics and measures for their performance measurement, etc.

6. Inventory Review and Reduction - Check inventory reduction policies.

7. Build Skills and Capabilities

8. Improve Product Design - Check the product configuration, follow standardization of number of parts, review the production processes.

9. Measures and Metrics

10. Continuous Improvement - Conduct RCA (Root Cause Analysis) and review trends.

Now, all these steps need to be conducted stepwise with certain overlaps, meaning some steps can be started when the previous ones have started but not yet finished. This is because it is based on the standard MPC framework, which is why certain steps need to be completed before others. Also, certain steps could not be done without completing previous steps. For example, you need to define lot sizing policies before setting inventory policies, flow layouts should be reviewed before automating the processes as someone has well said "Reengineer before you automate". Same logic goes for all steps.