Just-In-Time-Manufacturing-A-Comprehensive-Playbook - Level 1

Just-In-Time (JIT) Manufacturing – Level 1 Summary

This playbook outlines how to implement Toyota’s Just-In-Time manufacturing system—producing only what’s needed, when it’s needed—reducing inventory from 30–45 days to 2–5 days, cutting costs by 20–30%, and boosting efficiency.

Core Principles:

Benefits:

30–50% inventory reduction, 15–25% space savings, improved cash flow, >50% lead time reduction, higher product quality, and stronger supplier partnerships.

Challenges:

Vulnerability to supply chain disruptions, need for precise forecasting, extensive workforce cross-training, and overcoming organizational resistance.

4-Phase Implementation Roadmap (11–19+ months):

Key Enablers:

Success Factors:

The result is a lean, responsive production system with higher efficiency, lower costs, and improved customer satisfaction.