The Benefits of Just-in-Time Supply Arrangements

Just-in-time (JIT) supply arrangements have revolutionized the way that businesses manage their inventory. The goal of JIT is to eliminate waste and streamline operations by only ordering and receiving goods and products as needed during production. This approach stands in stark contrast to traditional inventory management systems, which rely on keeping large amounts of goods and products on hand.

To implement a successful JIT inventory system, businesses must have a strong understanding of their operations and the ability to respond quickly to changes in demand. In this article, we’ll dive into the benefits of just-in-time supply arrangements, their drawbacks, and how your business can effectively adopt a JIT strategy.

Just-in-Time Inventory Management

JIT supply arrangements have been a transformative force in the field of supply chain management. Multiple industries have since implemented a JIT approach in their operations, to varying levels of success.

Purpose of a JIT Inventory System

More and more organizations are adopting lean management strategies to reduce waste and increase efficiency. JIT inventory systems are one of the many strategies that a manufacturer could adopt. A JIT supply chain arrangement aims to align raw-material orders from suppliers with a company’s production schedules.

With a JIT inventory system, the company receives materials only as it needs them during the manufacturing process. This approach minimizes inventory and eliminates any unused or wasted goods, reducing costs.

If one of our customers is utilizing Just-in-Time inventory management, they only receive aluminum & stainless steel, sheet, plate, bar, tube, and long products when they need them.

History of JIT Production

JIT is a Japanese management technique that has roots dating back to the early 1970s. Following World War II, Japan sought to rebuild its industries while navigating critical challenges, like a lack of natural resources, land space, and cash flow. Toyota pioneered the JIT method to help optimize its manufacturing processes and maintain a lean operations strategy.

Taiichi Ohno, a Japanese engineer known as the father of JIT, perfected the approach and created the Toyota Production System. Using this approach, Toyota was able to navigate these complex challenges and optimize its plants for maximum manufacturing output and efficiency. As companies across Japan learned about JIT, they began to adopt the strategy. Western countries soon followed suit.

Understanding JIT Supply Arrangement

A JIT strategy ensures that there is just enough manufacturing inventory to produce what a company needs when a company needs it. The goal of a JIT supply arrangement is to achieve lean manufacturing, or the highest possible volume of production while reducing supply chain waste.

Keeping less inventory on hand lowers the cost of storing, procuring, and shipping goods and raw materials. By minimizing inventory costs, JIT allows companies to quickly respond to changes in demand, improve quality management, and optimize production processes. As a result, they can enjoy lower costs and higher profits.

Several industries, such as automotive, electronics, and retail, widely use JIT. Companies around the world, including Toyota, Apple, and fast-food chains like McDonald’s, have implemented JIT manufacturing into their supply chain management strategies. As a result, these entities have achieved greater efficiency and flexibility.

Advantages of Just-in-time Supply Arrangements

For businesses looking to streamline their supply chain operations, JIT supply arrangements can offer numerous benefits. By switching from bulk procurement to a lean manufacturing approach, companies can reduce costs, boost efficiency, and reduce waste. These advantages have positioned JIT manufacturing as an attractive option.

Operations Planning and Control

JIT supply arrangements can make supply chain planning and control much simpler to manage, reducing the burden for companies’ operations staff. Here are a few of the key advantages:

• Enhanced quality control: JIT places a strong emphasis on quality control in manufacturing, which can lead to improved product quality. Suppliers and manufacturers need to coordinate closely during the process. As a result, they receive goods and materials on time and with the right specifications.
• Improved production scheduling: For JIT to work, companies need a highly efficient and flexible production schedule. Businesses can transform production scheduling by syncing it with supplier deliveries.
• Increased productivity and agility: By reducing the time and resources needed for manufacturing, JIT inventory management enhances operational productivity. Companies can enjoy faster production and shorter runs. Furthermore, with less raw material stock, it becomes possible to implement product changes swiftly and with less waste.

Cost Savings

For companies that want to reduce waste and save money, purchasing materials in bulk is not always an effective strategy. Fortunately, JIT manufacturing is well known for its cost-saving benefits.

JIT purchasing strategies reduce inventory carrying costs by limiting a company’s stock. This frees up capital for investment in other areas of the business, supporting innovation. JIT also boosts production efficiency, reducing lead times, enhancing production scheduling, and therefore lowering production costs.

This approach requires suppliers to deliver materials and parts just in time for production, reducing the cost of holding large quantities of raw material. With better quality control, manufacturers can also reduce the risk of unused or damaged materials, which saves even more money.

Benefits of JIT Supply Arrangements

From aircraft manufacturers to boat dock makers and beyond, JIT purchasing is a powerful and beneficial approach for many industries. In addition to operations planning and control and cost savings, JIT manufacturing offers several other benefits, such as:

• Reduced waste
• Improved efficiencies in the production process
• A smoother production workflow
• Improved relationships and coordination with suppliers
• Improved ability to respond to consumer demand
• Improved storage space utilization
• Reduced manufacturing time
• Reduced work-in-progress time
• A lower rate of defects in output

Overall, JIT’s numerous benefits make it a valuable approach for companies looking to improve their production workflows. If your business wants to stay ahead in today’s rapidly evolving marketplace, adopting a JIT strategy can transform the way that you operate.

Risks of Just-in-time Supply Arrangements

While JIT supply arrangements offer numerous benefits for businesses, this approach does come with some risks. Businesses that adopt a JIT strategy are vulnerable to disruptions in the supply chain and are dependent on their suppliers. To determine whether JIT is right for your company, it is important to be aware of the potential risks and challenges.

Risks of JIT Strategy

While JIT supply arrangements offer many benefits, they also come with many potential risks. When analyzing a JIT strategy, it is important to carefully consider the following challenges:

• Lack of preparedness: JIT requires a high level of planning and preparation. A lack of readiness can lead to supply chain disruptions and serious inefficiencies.
• Supply chain disruptions: JIT relies on a smooth-running and highly efficient supply chain. Any disruptions can have a major impact on production and lead times, making it difficult to procure the materials that a business needs.
• Unexpected price changes: JIT requires close coordination with suppliers and careful planning. Sudden price changes can have a significant impact on a company’s bottom line.
• Local sourcing costs: Companies may need to source materials locally or adopt a vendor-managed inventory approach. This can result in higher costs compared to sourcing from lower-cost regions that are farther away.
• Time pressure: JIT requires a fast-paced approach and a high level of urgency, which can result in time pressure and increased stress for staff.
• Supplier dependence: JIT relies heavily on suppliers, and a dependence on a single supplier can result in production disruptions and increased risk.
• Acts of nature: JIT requires a stable and predictable supply chain. Unexpected events such as natural disasters or extreme weather events can disrupt the supply chain and harm production.

JIT Challenges to Overcome

To be successful in JIT, a business needs to prepare itself to address significant and unexpected challenges. For example, if a supplier experiences unexpected production disruptions, the company using JIT may not receive the necessary materials in time. To overcome this challenge, they must work closely with suppliers to minimize the risk of disruptions and ensure timely delivery.

If the sole supplier of a critical material or component goes out of business or experiences financial difficulties, the company relying on JIT needs to act quickly. To mitigate this risk, the company must work to diversify its supplier base, develop new relationships, and establish contingency plans.

JIT also requires significant planning and preparation. If a company has not adequately planned for seasonal fluctuations in demand, it may struggle to meet demand during peak periods. Companies must invest in effective planning and forecasting tools to prepare for changing patterns.

Disadvantages of JIT Supply Arrangements

JIT supply arrangements have several disadvantages, including a need for a reliable supply chain and accurate demand planning and sales forecasts. Disruptions in the supply chain, which many industries experienced due to COVID-19, can result in production issues and increased costs.

Effective planning and forecasting processes are essential for JIT’s success, as the strategy requires a clear understanding of consumer demand. Working with the right supply chain partner can help companies effectively implement a JIT inventory strategy.

How to Adopt a Just-in-Time Inventory Strategy

For many companies in Canada, a JIT inventory strategy’s benefits outweigh the potential drawbacks. If you want to streamline your supply chain, implementing a JIT system can be an optimal strategy. To ensure a successful transition, however, it is important to approach the adoption process strategically and methodically.

Implementing a JIT Inventory Strategy

For JIT to be successful, you need to consider your business’s requirements. You need to plan for potential challenges and develop a method to accurately forecast your procurement needs. By considering these factors, you can facilitate a smooth implementation and maximize the benefits of JIT inventory management.

Assess readiness by evaluating turnarounds, forecasting, flexibility, vendor relationships, and workforce readiness:

• Ensure quick and efficient manufacturing turnarounds to minimize waste and reduce costs.
• Implement accurate forecasting to understand customer demand and make informed production decisions.
• Be flexible to adapt to changing demand patterns.
• Maintain a strong relationship with reliable suppliers for timely delivery of materials.
• Train employees on the new system and processes and make sure they are ready for a fast-paced JIT environment.

Techniques to Consider

Many techniques can help your business implement an effective JIT strategy. Effective implementation of these measures can enhance production efficiency and reduce costs:

• Ordering: Implement regular and frequent ordering of materials from suppliers in accordance with actual customer demand.
• Reduced setup time: Find ways to reduce the time it takes to change production runs. Minimize downtime where possible.
• Small lot sizes: Produce smaller quantities of products at a time to minimize excess inventory.
• Load uniformity: Balance workloads across production areas to reduce idle time and increase efficiency.
• Diversified skills: Encourage workers to develop multiple skills and promote cross-training so they can perform in-demand tasks.
• Ongoing maintenance: Maintain and improve your processes regularly to keep the JIT system running efficiently.
• Logical plant layout: Re-design your production facilities for optimal flow and efficiency.
• Worker immersion: Encourage workers to actively participate in the JIT process so they can better identify and address issues.

Pitfalls to Avoid

When adopting JIT inventory management, it’s crucial to prepare your organization first. Focus on evaluating your current operations to determine if your company is ready to transition from a just-in-case inventory strategy to JIT.

You should also avoid the following pitfalls:

• Over-reliance on suppliers
• Poor communication with suppliers
• Inadequate forecasting
• Lack of contingency plans for supply chain disruptions

By preparing your organization and avoiding common mistakes, you can successfully adopt lean manufacturing principles and reap the benefits JIT offers.

Ready to Get Started?

JIT inventory management can be a very effective method. However, implementing a successful JIT system does require accurate forecasting, careful planning, and flexibility.

Despite these challenges, many adopters of JIT strategies have gained a competitive edge in their respective markets. If you want to optimize your operations, consider JIT as a valuable addition to your toolbox.

Interested in implementing Just-in-Time inventory management? Not only does Diversified Ulbrich offer JIT supply arrangements, but our in-house processing capabilities allow us to cut-to-length and coat material, as needed.

Browse our inventory of stainless steel, aluminum, and specialty metal products, all available JIT from Canada’s most Diversified metal service center.