JUST IN TIME AND QUICK RESPONSE

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 Questions
1. What does JIT mean ?

2. What is Quick response means?

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 INTRODUCTION
 Just-In-Time is a Japanese manufacturing management method developed in

1970s. It was first adopted by Toyota manufacturing plants by Taiichi Ohno.

 Just-in-time (JIT) production means producing the right item at the right time in

the right quantity.

 The just-in-time (JIT) inventory system is a management strategy that aligns

raw-material orders from suppliers directly with production schedules.

 The principle of Just in time (JIT) is to eliminate sources of manufacturing

waste by getting right quantity of raw materials and producing the right
quantity of products in the right place at the right time.

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 Just-in-time manufacturing (JIT manufacturing) is a

production model in which items are created to meet

demand, not created in surplus or in advance of need.
The objective of JIT is to produce a continuous flow of

value so that the customer can pull.

The JIT system comprises kanban and production leveling.

JIT supports quick response to customers, a better sense of

takt time, and abnormality control.

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 Toyota introduced JIT in response to very concrete problems

including:
 Fragmented markets demanding many products in low

volumes
Tough competition

Fixed or falling prices

Rapidly changing technology

High cost of capital

Capable workers demanding higher levels of involvement

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 Organizations adopt the JIT approach to increase

efficiency, reduce costs and speed up product delivery.

In a push-based system, inventory needs are forecasted in

order to meet consumer demand.

In a pull-based, consumer demand drives inventory needs.

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 Why JIT?
 Conventional mass manufacturers “push” the product through

the system irrespective of actual demand.

 A master schedule is made based on projected demand.

 Daily orders are given to each department to make the parts

final assembly will require.

 Because changeover times are long, large batches are common.

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 ELEMENTS OF JUST IN TIME
 the basic elements of JIT manufacturing are:

• Continuous improvement. ...

• Eliminating waste. ...

• Good housekeeping - workplace cleanliness and organisation.

• Set-up time reduction - increases flexibility and allows smaller

batches. ...
• Levelled / mixed production - to smooth the flow of products

through the factory.

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 PRODUCTION PHYSICS
 Cycle Time = Work in Process (WIP) ÷ Throughput, or

Throughput = Work in Process (WIP) ÷ Cycle Time

 Throughput is the average output of a production process

Cycle time also called average cycle time, flow time, and

throughput time for a given routing .

Work in process is the inventory accumulated between the

start and end points of a routing.

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 Basic Principles of JIT
 JIT production follows a few simple rules.

1. Don’t produce something unless the customer has

ordered it.

2. Level demand so that work may proceed smoothly

throughout the plant.

3. Link all processes to customer demand through simple

visual tools (called kanbans).

4. Maximize the flexibility of people and machinery.

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 The JIT System
 The components of the JIT system are:

◾ Kanban: A system of visual tools (usually signal cards) that

synchronize and provide instruction to suppliers and customers both
inside and outside the plant.

◾ Production levelling: This supports standardized work and kaizen.

• The goal is to produce at the same pace every day so as to

minimize the peaks and valleys in the workload.

• Paradoxically, production levelling also supports quick adaptation

to fluctuating demand.

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 Advantages of JIT The disadvantages of JIT
 JIT inventory systems have several advantages  The disadvantages of JIT inventory

over traditional models. systems involve potential disruptions in

 Production runs are short, which means that the supply chain.

manufacturers can quickly move from one  If a raw-materials supplier has a

product to another. Also, this method reduces breakdown and cannot deliver the goods

costs by minimizing warehouse needs. promptly, this could conceivably stall the

 Companies also spend less money on raw entire production line.

materials because they buy just enough  A sudden unexpected order for goods

resources to make the ordered products and no may delay the delivery of finished

more. products to end clients.

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 1.2 kanban system
 A kanban is a visual tool used to achieve JIT production.

 A kanban is an authorization to produce or withdraw and may

also contain related information such as

◾ The supplier of the part or product

◾ The customer

◾ Where to store it

◾ How to transport it (i.e., the size of the container and the method
of conveyance)
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 There are two kinds of kanban:

◾ Production kanban, which specifies the kind and quantity

of product that the upstream process (supplier) must produce.

◾ Withdrawal kanban, which specifies the kind and quantity

of product that the downstream process (customer) may
withdraw

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 6 Golden Rules of Kanban
 There are 6 golden rules of kanban, and in some cases, they are also prerequisites to implementing kanban.

1. Downstream processes always withdraw from upstream processes. More to the point, if there is no

withdrawal, kanban material is not moved.

2. Upstream processes produce only when instructed. In other words, nothing is made without a Production

Kanban signal.

3. Defects must never be passed on to the next process. This requires each worker to self inspect their work

instead of waiting for some “final inspection process” to examine the product.

4. Kanban should be attached to the actual part containers. These containers, as we’ve already learned, may

be things like bins or carts.

5. In order for kanban to work properly production must be leveled.

6. The best kanban is no kanban. Since kanban directly relates to inventory, we should always aim to reduce the

number of kanban in the system. Eventually, our ideal state should always be to have a production system that

receives orders at the first process and then flows the inventory through the value stream without any delay or

queue. When this is the case, no kanban will be needed at all.

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 1.3 Quick Response
 Quick Response is the collaboration program that enables

the seller to respond rapidly to customer’s demand at the changing

market.
 It was first employed by U.S. apparel industry in mid-1980’s to solve

the inherent problems that the apparel industry has had in history.
 Under the volatile market situation with short product life cycle, most

apparel manufacturers have suffered high stocking cost and sales loss
due to the unbalanced inventory level.

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  Quick Response is considered to be the combination of Just-In-

time system and advanced information technology, and its three

key functions are lead time reduction, real time information
application, and flexible manufacturing.
Many business practitioners have recognized that Quick

Response brings the supply chain system on the effective

inventory management and logistics improvement.

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The benefits of the QR in the industries are:
 The QRM process looks at how lead times across the company

can be reduced to increase productivity.

 When a company has implemented QRM it should be able to

realize a reduction in lead times of up to 95%, a reduction in

finished product cost of 30 %, an improvement in on-time
delivery performance in excess of 60 %, and reduction in scrap
and rework of up to 80 % or more.

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 • Reduction in pipeline inventories.

 The greater possibility of garments designs and colours being

acceptable to the consumer by moving styling closer to the

sales date.
 The ability to re-calculate SKU demand at retail and make

frequent reorder during the season, thus reducing stock outs and
markdowns.
 Greater competitiveness for domestic producers facing

increased level of imports.

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 1.3 Technologies used to track
merchandise
1. Radio Frequency Identification (RFID) refers to a wireless
technology comprised of two elements: tags and readers. The
reader is a tool that has one or more antennas that release radio
waves and receive signals back from the RFID tag.
 In the sector of textile and clothing, radio frequency identification

(RFID) is one of the most important technological innovations, it

is used in manufacturing, inventory control, warehousing,
distribution, logistics, automatic object tracking and supply chain
management.

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 Needs and Requirement of RFID Systems:
 RFID technology is considered as key to getting 100% reliability uniting to

the location of a delivered item at any given time, and the time at which it
attained its destination. The information is precious to the logistics
company and to garment manufacturing companies which depends heavily
on logistics.

1. Industries offering industrial washing services, such as those which

washed uniforms and/or hospital garments and linens;

2. Industries offering clothing scattering services;

3. Wholesalers;

4. Retailers.

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 Companies Provide RFID Technology to the
Textile and Apparel Supply Chain Management:
1. RFID Thread, manufactured by ADETEX.ID, looks and feels much like a common

thread, but it holds digital details and can be scanned from a distance, using RFID
technology. It lasts for the garment’s lifetime, reduces waste throughout the whole
supply chain.

2. Circular ID, manufactured by Eon, is a platform which collates applicability garment-

specific data including: materials, origin, price, style, and recycling commands. It was
acquired to improve transparency and conversation throughout fashion supply chains.

3. Avery Dennison gives RFID technology to digitize clothing and footwear items, and

to link these with social network.

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 Benefits / Advantages of RFID Systems:
1. Tracing assets and managing inventory.

2. Saving time, money through automation.

3. Enhancing data accuracy and availability.

4. Improving health and safety.

5. Better control of production.

6. Enhanced quality, traceability.

7. Increased revenues.

8. More in-depth management details.

9. There are more profits that the retail stores, as well as the consumers can enjoy..

10. RFID also remarkably improves the time needs to take inventory.

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 Application of RFID in Fashion and
Apparel Industry:
 Inventory management:

 Production control:

 Supply chain management:

 Retail management:

 RFID used in fitting room:

 RFID tags for care labelling:

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 Top Five Fashion Companies
Utilizes RFID Technology
 Amazon

 ZARA

 H&M

 Decathlon

 BJC HealthCare

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 Exam question answer
1. Co-branding: The practice of using the
established brand names of two different
companies on the same product. Co-branding.
Co-branding occurs when two established brand
names of different companies are used on the
same product. Co-branding offers many
advantages. Because each brand operates in a
different category, the combined brands create
broader consumer appeal and greater brand
equity. For example, Benjamin Moore and Pottery
Barn joined forces to create a special collection of
Benjamin Moore paint colors designed to
perfectly coordinate with Pottery Barn’s unique
furnishings and accents
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Tha

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