Just in Time (JIT) in Garment Manufacturing: Concepts and Benefits
Shubham Anil Jain
Aditya Birla Fashion and Retail Limited
Bangalore, India
Email: shubhamajain125@gmail.com
Introduction:
JIT (just in time) is the reverse of JIC (just in case). JIT is an illustration of a pull system, while JIC is an illustration of a push system. JIT refers to creating the appropriate part in the appropriate quantity at the appropriate time, which lowers production waste. The goal is to provide a constant flow of value that the consumer may draw from. JIT promotes rapid customer response, improved takt time perception, and abnormality control. Kanban and heijunka, or production levelling, are components of the JIT system. JIT is a management concept and a tool that helps a business’ internal operations adjust to rapid changes in demand patterns. Just-in-Time (JIT) in garment manufacturing focuses on producing garments based on actual customer demand, minimizing inventory, and reducing lead times.
Concept of Just in Time (JIT): Cash flow is crucial for any organization’s expansion. Reducing stock or inventory can enhance cash flow since excess stock is a kind of waste, stock has money, and this stock blocks the money. By supplying material in the proper quantity and at the proper time, Just in Time (JIT) helps to decrease inventory, preserving a healthy cash flow and promoting industry expansion.
Inventory is the foundation of Just in Time (JIT), thus we may implement JIT in any industry by supplying inventory in the proper quantity, at the proper location, and at the proper time. It is basically a management strategy where the function of the merchandiser and sourcing personnel is crucial. In order to maintain this strategy, a strong follow up is needed. Daily supply of the material in the necessary amount, but not too much. Everyone should be a little bit proactive about the necessity in order to implement JIT.
For instance, if you use just-in-time technology, the executive of the cutting department must notify the store department before that day whenever the cutting department needs fabric roles. Otherwise, there won’t be enough supplies the following day.
To ensure that supplies are provided consistently and without delay, the JIT technique needs producers to have strong relationships with suppliers and supply chain visibility. Manufacturers must also adopt uniform internal procedures with a focus on effectiveness and efficiency. Additionally, regardless of how effectively business operations and procedures are currently performing, they must constantly search for methods to improve them.
Characteristics of JIT:
a) Pull
Toyota saw that the first necessity for just-in-time production was to make it possible for all processes to rapidly and accurately learn the timing and number of parts that were needed. JIT focuses on the synchronization of all processes in order to complete the essential products at the appropriate time. This was achieved by connecting all processes in reverse order and using the components pullout by following process principle. Specifically, it means that an item is only considered necessary for an upstream process when a downstream process actually physically removes it from its position. What is frequently referred to as “pull” is this.
b) One-Piece Flow The second feature of just-in-time manufacturing is that all operations go closer to the point when each can manufacture just one item, can deliver it one at a time, and can also hold just one item in stock between the equipment and the operations. This means that no process is permitted to create more than necessary and to carry additional inventory between operations. In other words, the manufacture and delivery of lots are excluded from all operations. Please be aware that while JIT prefers one-piece flow, it is not a requirement. This means that as long as you consistently work towards one-piece flow, you can start with pull.
c) Smoothing or Levelling: The levelling of output is the third essential component of just-in-time. The upstream processes, including those at subcontractors and suppliers, would constantly need to operate at maximum capacity or keep an excessive amount of inventory if the quantity withdrawn by the downstream process varied significantly. As a result, the downstream process needs to level the parts withdrawal. It’s important to note that in this situation as well, the initial market demand can be levelled utilizing JIT’s mix-level loading method, known as heijunka. Non-level demand just necessitates additional heijunka; it does not preclude the viability of JIT.
d) Respect for People: The Toyota approach incorporates respect for people into every aspect of operation. This feature, among others, intends to provide team members more autonomy by giving them more authority and responsibility, having competent employees actively participate in running and developing their workshops, and allowing them to participate in creating improvements. This means that any genuine JIT system enables operators to operate and play a crucial role in its execution, identify flow irregularities, halt production, and take part in later initiatives aimed at improving flow and production control.
Benefits of JIT:
1. Reduced Space Needed – JIT allows for a quicker turnover of stock, which reduces the amount of warehouse or storage space required to hold products or supplies. In the end, less storage space will need to be purchased or rented by your company, saving money that can be used for other aspects of the operation.
2. Less Expensive Investments –
JIT inventory management is a great solution for small production facilities that lack the resources to buy large quantities of stock all at once. You can keep a steady and healthy cash flow by just ordering stock supplies as needed.
3. Waste Elimination/Reduction –
By turning through stock more quickly, broken or outdated goods are avoided from languishing in storage, cutting down on waste. Once more, this prevents the purchase of superfluous stock and lessens the need to replace it, saving money.
Conclusion: Using a just-in-time (JIT) inventory system, suppliers can place orders for raw materials that are directly in line with production schedules. By only ordering the things they actually need for the production process, businesses can cut down on inventory expenses while increasing efficiency and reducing waste. Producing using this technology necessitates precise demand forecasting. Just-in-Time (JIT) in garment manufacturing ensures high quality, fosters continuous improvement, and optimizes workflows to enhance efficiency and customer satisfaction.
Founder & Editor of Textile Learner. He is a Textile Consultant, Blogger & Entrepreneur. He is working as a textile consultant in several local and international companies. He is also a contributor of Wikipedia.
