Main elements of lean thinking and just-in-time concepts in operations

Lean Manufacturing and JIT

JIT

Evaluate three of the main elements of both lean thinking and JIT. How can these concepts be used for effective planning and control of an operation? How are these two concepts different? How can the differences in each concept be overcome to achieve maximum efficiency benefits of both lean thinking/JIT systems?

Lean thinking was introduced to improve the traditional 'batch-and-queue' manufacturing process. One of the core principles of lean manufacturing is that of 'one-piece flow,' a system that "rearranges production activities in a way that processing steps of different types are conducted immediately adjacent to each other in a continuous flow" (Lean thinking and methods, 2012, EPA). This is designed to eliminate wasteful movements of workers and compress the time required to produce each, individual component of the manufactured product. Lean thinking strives to maximize efficiency of both time and resources. Lean thinking is also a zero-defect philosophy. Just like unnecessary movements or steps, defects result in waste (Lean thinking and JIT Operations, n.d, PowerPoint). Goods and services that must be rejected because they do not meet customer needs or company standards cost the company money.

To achieve this ambitious goal of zero defects, lean thinking requires extensive study of company operations, to understand how to use resources, including labor, to the maximum degree of efficiency. Workers are trained in many tasks, so they can be easily moved on the shop floor. They are also able to perform on-the-spot quality inspections, to reduce waste through addressing defects or slowdowns in the production process immediately. Continuous improvement is demanded, which also demands highly-trained workers, to constantly suggest ways to make the production process better (Lean thinking and JIT Operations, n.d, PowerPoint).

Just-in-time (JIT) manufacturing is based upon the 'pull' production method. In JIT, inventories are kept at a minimum during the manufacturing process, and component parts are only assembled at the moment of need. JIT is based upon the principles of accuracy, given that no excess inventories are kept in the case of error; speed to ensure that that component parts are brought to the production facility in a timely manner, and urgency, so that all problems -- large and small -- are quickly resolved. Customer orders are also postponed to the last, possible minute to ensure that the inventory demanded is truly necessary (Lean thinking and JIT Operations, n.d, PowerPoint).