Kanban implementation between a heavy manufacturing department and foundry suppliers

Implementation of JIT methods often begins in an assembly department with the introduction of kanban. Only when the implementation program begins in the fabrication areas supplying the assembly department do the most serious problems with JIT arise. The farther back in the supply chain JIT is implemented, the harder problems become, especially in the management of outside suppliers such as foundries where economics still requires the batching of jobs. Faced with supplying a tractor assembly line, department 500, a producer of heavy cast iron transmission cases using transfer lines and MRP, implemented kanban not only to supply the assembly area, but also back to their own supplying foundries. The results were positive and suggest a need for creativity in JIT implementation rather than a strict adherence to a cookbook approach.     

Organizational modifications to support JIT implementation in manufacturing and service operations

This study investigates JIT implementation practices and performance in manufacturing and service organizations in the US. Literature related to JIT usage and performance in both sectors is reviewed. A field study is then conducted to investigate the actual implementation experiences of a selected group of service and manufacturing users of JIT. Our findings from the literature and the field study are used to develop four research hypotheses that are tested using survey data from 130 manufacturing and 61 service firms. Manufacturing and service firms that had engaged in modifications such as operator and management training and improving linkages with suppliers prior to implementing their JIT systems experienced less implementation problems and achieved higher levels of success than firms that placed less emphasis on these modifications. This paper details and discusses these and other results from our study. In addition, managerial implications of our findings are presented.     

A structured methodology to implement judiciously the right JIT tactics

In order to enhance the competitiveness and efficiency of manufacturing operations, many companies arc looking at implementing key strategic technologies. Two of the most predominant programs are ‘just-in-time’ and ‘synchronous organizations’. However, their impacts on improving quality and reducing time-to-market have been mixed. It is not very clear why, in some cases, results are poor, when in a similar situation, programmes have proved to work well. There are conflicting reasons reported for such a discrepancy. Some have argued that during J IT implementation either a right mix of tactics was not selected at the outset or the process was not carefully monitored to see whether a mid-course correction or change in tactics was necessary. In order to (a) protect the manufacturing and strategic teams from making the same/similar mistakes and (b) sustain a series of successful activity throughout during the strategic implementation cycle, this paper outlines a structured methodology. The method utilizes a matrix-based procedure to dynamically (over time) measure the effectiveness of a line of JIT tactics against the organization's principles and objectives. The operating procedure suggests first (a) using a method for monitoring the changing conditions of market and business and then (b) using the metrics to guide the management with a new line of tactics that might have better impact on the newly aligned company goals. In an effort to help managers and engineers decide on a proper line of tactics to implement JIT, a line of JIT quality matrices (JQM) is developed. JQM provides a framework to guide group managers to ‘plan, pick and choose’ a set of effective JIT techniques. An approach similar to quality function deployment (QFD) is used to generate the JIT house and their corresponding JQM matrices. With the JQM-based structured methodology, managers can design the best line of JIT strategy blended with JIT theory and adapted to the manufacturing environments in which it is expected to operate.     

HRM practices of JIT firms in Canada

Many firms have adopted the just-in-time (JIT) philosophy to compete successfully in the global environment. The literature suggests that die success of JIT implementation depends on sound human resource management (HRM) practices that will attract, maintain, and retain employees with the required workforce characteristics. However, only a few field studies investigate the effectiveness of such practices. This empirical study examines HRM practices of 69 JIT manufacturing firms in Ontario, Canada. Specifically, it identifies important workforce characteristics, recruitment sources and selection instruments used by JIT firms. It also evaluates die degree of change in training, compensation, employee retention, and labour relations practices in the firms since JIT implementation. The level of attainment of various expected outcomes of JIT implementation and die competitiveness of the JIT firms are investigated. Problems faced by HRM managers are also discussed.     

Materials receiving capacity and inventory management

This paper analyses the optimal level of materials receiving capacity for a manufacturer that receives deliveries from many suppliers. Inventory levels and inventory carrying costs depend on the frequency of deliveries and thus, on the materials receiving capacity. An analytic model that captures the tradeoff between inventory costs and materials receiving costs is presented and discussed. The receiving cost is modeled as increasing in discrete jumps of varying sizes whenever materials receiving resources are added. Practical issues in implementing the model are highlighted and methods to reduce the marginal materials receiving cost are discussed. The paper also discusses connections to the JIT approach for production environments where materials receiving is heavily automated.     

Determining the Critical Elements of Just-In-Time Implementation

There are a limited number of papers dealing primarily with the implementation aspect of JIT. While the literature shows almost general agreement on the critical elements of JIT implementation, few empirical studies exist to support the proposed elements. The purpose of this study is to identify the elements of JIT implementation that are required to ensure successful implementation. A number of implementation elements were identified and subsequently grouped into a hierarchical structure consisting of four broader elements. Criteria were selected as measures of the level of implementation success. Analysis revealed that only a few of the identified elements were indeed required for successful JIT implementation.     

Implementation of just-in-time methodology in a small company

This paper describes the implementation of JIT in a small manufacturing company and the benefits that resulted for the company's operations. Preliminary analysis identified various problems in the existing manufacturing operations. The pre-implementation and post-implementation conditions of the company arc detailed. The achievements of the JIT implementation included a reduction in material traversing, reduced lead limes and inventories leading to an overall reduction in the cost of manufacturing. A smooth flow of material from the raw material stage to the finished product stage was established. Three separate product lines were combined into a flexible manufacturing assembly line. With the adoption of a holistic approach to JIT implementation, it was found that even a small company can make significant strides towards world class manufacturing status. The experience gained by the company can encourage and benefit other small companies to embrace the JIT approach.     

Production planning in a MRP/JIT repetitive manufacturing environment

Some literature suggests that the best approach to production planning is a complete implementation of just-in-time. It has also been suggested that JIT replaces material requirements planning, and computerized procedures are an unnecessary complex burden on management especially in a highly repetitive environment. This article examines the JIT programme at the John Deere Engine factory. In 1985 the factory began a JIT programme with the belief that it would replace their MRP system. The results of the JIT programme are examined and management's conclusion that the best approach is a blend of JIT and MRP is explored.     

Just-in-time purchasing: an empirical investigation

The just-in-time (JIT) literature suggests that, for JIT to be successful, a manufacturing firm has to make changes in its purchasing operations. However, empirical examination of the JIT purchasing related issues is limited. For example, a literature search identified 49 JIT purchasing articles. Of these, only 14 are empirical studies; two dealing with statistical testing of a few JIT purchasing issues. This comprehensive empirical study is undertaken to investigate (a) changes in the purchasing attributes since JIT implementation, (b) supplier evaluation cri-teria, and (c) problems with JIT purchasing implementation. Statistically significant changes are observed in 28 out of 32 attributes identified in the literature, suggesting that the manufacturing firms are successfully implementing JIT purchasing programmes. Of the 14 supplier evaluation criteria, the empirical investigation shows nine of them being important. Erratic demand for the product and customized product are found to be problematic (but not very problematic as suggested in the JIT literature( in JIT purchasing implementation.     

A FRAMEWORK AND MEASUREMENT INSTRUMENT FOR JUST-IN-TIME MANUFACTURING

While Just-in-Time (JIT) manufacturing has emerged as one of the major tools to enhance manufacturing competitiveness, no attempt has been made to develop a reliable and valid measurement instrument for empirical research in JIT. Without such an instrument, generalization beyond the immediate sample is difficult or misleading. We have proposed a JIT framework and developed a valid and reliable instrument with 16 summated scales for dimensions that capture essential aspects of JIT useful in assessing its impact in manufacturing environments. In addition, we discuss in detail the interactive nature of JIT practice. And, we propose a step-by-step approach to reliability and validity testing. Four JIT practices (equipment layout, pull system support, supplier quality level, and Kanban) are identified as major contributing factors to JIT performance.     

Human resource management in the just-in-time environment

Successful just-in-time (JIT) implementation requires a multiskilled group-oriented and self-disciplined workforce with good quantitative skills. Little discussion exists in the JIT literature concerning the development of such a workforce. The human resource management (HRM) literature deals with employee issues but does not identify strategies for achieving a JIT workforce. In order to identify appropriate HRM strategies for a JIT environment, a comprehensive model is presented to show the critical linkage between JIT and HRM. Interactions between legal issues, management and union, and human input are examined. The impact of US labour laws on HRM practices is discussed and contrasted with Japanese practices. The literature review of HRM-related JIT articles suggests that HRM practices in the areas of staffing, training and development, compensation, and employee retention can be used to develop an effective JIT workforce. The article will help production managers to understand the impact of specific HRM strategies that are appropriate for developing a JIT workforce.     

Real‐Time Revision of Order Quantities with Capacity Constraint: A Single Period Model

Manufacturing firms would like to maximize customer satisfaction by providing them with what they need when they need it. This, however, would mean continual variations in production quantities, and component orders from suppliers. A flexible manufacturing system can help alleviate costs related to modification of production quantities. The capacity of such a system, however, has to be limited because of high investment cost. Further, unless there is a long‐term relationship, suppliers may levy a high surcharge for last minute changes in order size. We model a hybrid control policy comprising an advance (pre‐production) order size agreed upon with suppliers, and a provision for real‐time order revision at a given rate of surcharge. We show that a rank‐order of products can be used for real‐time revisions, and that a strong buyer‐supplier relationship that keeps these surcharges low can actually help increase profits for both parties. We study issues such as compatibility between JIT and flexibility, and the impact of market conditions on overall profitability.     

The impact of critical success factors of JIT implementation on organizational performance

Much has been written and publicized about the virtues of JIT philosophies during the past decade. However, relatively limited empirical research has been reported con-cerningJIT implementation on organizational performance. This study presents the results of an empirical study which utilized both concrete financial accounting data and a broad cross-sectional survey as measures of organizational performance to determine the impact of each JIT implementation requirement factor to organizational performance. Communication between production and marketing departments was identified as a critical factor for increased inventory turnover and work-in-process inventory turnover, while employees' participation and the bottom-up management approach were determined as significant factors for improving quality and flexibility. The results of this study imply that in JTT environment personnel management practices, such as bottom-up management encouraging employees participation, and organization management such as a communications linking the production and marketing departments, are more important than JIT practices themselves.     

Adoption of just-in-time based quality assurance and purchasing practices

Feasibility of transforming purchasing and quality control operations from conventional to just-in-time (JIT) practices is discussed. The study is confined to the dock-to-stores area of an engine manufacturing plant. Components used in the study are selected from a representative sample of inventory classes, commodity groups and agreement types with vendors. A time/cost analysis is carried out for the components selected so as to evaluate the cost effectiveness of the conventional purchasing and quality control. Findings on savings in terms of inventory-related costs and inventory turnover through the implementation of JIT practices are reported. A transformation framework is then developed to determine the suitability of individual components for JIT based practices. Cases are presented to demonstrate the functioning of the framework.     

Impact of Information Technology Integration and Lean/Just‐In‐Time Practices on Lead‐Time Performance*

Managers seeking to improve lead‐time performance are challenged by how to balance resources and investments between process improvement achieved through lean/just‐in‐time (JIT) practices and information technology (IT) deployment. However, extant literature provides little guidance on this question. Motivated by both practical importance and lack of academic research, this article examines empirically the relationships among interfirm IT integration, intrafirm IT integration, lean/JIT practices, and lead‐time performance using data from IndustryWeek's Census of Manufacturers ( IndustryWeek, 2006 ). The results provide several new insights on the relationship between IT integration and lean/JIT practices. First, the study confirms that implementing lean/JIT practices significantly reduces lead time. Second, lean/JIT practices mediate the influence of IT integration on lead‐time performance. This suggests that process improvements that result from lean/JIT practices are important contributors to the success of IT integration. Even companies that have experienced success in reducing lead time through lean/JIT practices may benefit from IT integration practices such as those embodied in enterprise resource planning systems. The findings provide managers with empirical evidence and a theoretical framework on the balance between lean/JIT and IT for effecting improvement in lead‐time performance, thus offering practical guidance on this important question. Future research is needed to extend the lean/JIT practices in this study to supply chain practices and explore the relationship between supply chain practices and IT integration.     

Implementation of just-in-time in a small company: A case study

This paper deals with the implementation of JIT in a small company in Taiwan that produces different kinds of automobile lamps such as rear combination lamps and front turn signal lamps. JIT systems have tremendous effects on all operations of a firm, including design, accounting, finance, marketing, distribution, etc., and thus are of interest to all levels of a firm's management. Realizing the success of JIT, large-scale manufacturing companies all over the world have implemented JIT in their production systems with the objective of improving their competitiveness. Nevertheless, small and medium enterprises SMEs play a major role in the national economy. However, JIT has not received serious attention from SMEs. Realising the importance of improving the performance of SMEs, a case study is presented to motivate practitioners to implement JIT in their SMEs. In addition, future research directions in the areas of implementing JIT in SMEs are presented.     

An information system for Just-In-Time

In recent years, U.S.'s worldwide industrial and economic leadership has been seriously challenged by many foreign countries. In order to counter the problem, many U.S. manufacturing companies have sought effective materials management systems such as MRP and the ‘Just-In-Time’ (JIT) system as used by many Japanese companies. Even through many practitioners and academicians have been studying the JIT concept and have recommended ways of adapting the concept to the U.S. manufacturing environment, not very many organizations are enjoying benefits of JIT system in full scale because of misunderstanding of information needs in JIT system. The objectives of this paper are (1) to identify information requirements of the materials management systems under JIT concept, (2) to compare them against the requirements under MRP system, and (3) to propose an integrated management information system to support materials management system in JIT environment. The goal of this paper is to facilitate more effective implementation of the JIT system, and stimulate further research on the subject matter.     

Selection of supply portfolio under disruption risks

This paper deals with the optimal selection of supply portfolio in a make-to-order environment in the presence of supply chain disruption risks. Given a set of customer orders for products, the decision maker needs to decide from which supplier to purchase custom parts required for each customer order to minimize total cost and mitigate the impact of disruption risks. The selection of suppliers and allocation of orders is based on price and quality of purchased parts and reliability of delivery. The two types of disruption scenarios are considered: scenarios with independent local disruptions of each supplier and scenarios with local and global disruptions that may result in all suppliers disruption simultaneously. The problem is formulated as a single- or bi-objective mixed integer program and a value-at-risk and conditional value-at-risk approach is applied to control the risk of supply disruptions. The proposed portfolio approach is capable of optimizing the supply portfolio by calculating value-at-risk of cost per part and minimizing expected worst-case cost per part simultaneously. Numerical examples are presented and some computational results are reported.     

JIT purchasing: attribute classification and literature review

To find critical JIT purchasing attributes for manufacturing industry, 56 refereed articles are reviewed. These articles are categorized as conceptual, case and empirical studies. Thirty-four attributes are thus identified. An input-output model is developed to classify these attributes. The inputs to JIT purchasing environment consists of buyer, supplier and joint buyer-supplier actions with 13, six and six attributes, respectively. The interaction between these attributes leads to the JIT purchasing environment. Output of this environment consists of nine attributes. By using the frequency of citation of an attribute as a measure of its importance, consensus is found among conceptual and case studies regarding those attributes of JIT purchasing considered critical. However, many of these attributes have not been investigated empirically, while others have not been rigorously examined. Common supplier evaluation criteria are identified. Benefits and problems with JIT purchasing implementation are discussed. Analysis suggests the need for comprehensive and statistically rigorous empirical studies.