Just In Time (jit) is a manufacturing philosophy that has important implications in cost management. The basic idea of Just In Time is very simple, the production only done if there is demand. A production process will produce only when signaled by the next process. As a result, waste can be removed on a large scale, in the form of improved quality and lower production costs.
Just In Time (jit) is a manufacturing philosophy that has important implications in cost management. The basic idea of Just In Time is very simple, the production only done if there is demand. A production process will produce only when signaled by the next process. As a result, waste can be removed on a large scale, in the form of improved quality and lower production costs.
Just In Time (jit) is a manufacturing philosophy that has important implications in cost management. The basic idea of Just In Time is very simple, the production only done if there is demand. A production process will produce only when signaled by the next process. As a result, waste can be removed on a large scale, in the form of improved quality and lower production costs.
PPAK Fakultas Ekonomi dan Bisnis Universitas Jenderal Soedirman 2014 PENDAHULUAN
I. Background The Emergence of JIT Today, the market is characterized by the increasing of products that consumers want and decreasing the life cycles of a product. This condition requires a new production strategy, because the old strategy thich is the system of mass production can not meet this challenge. Traditional pemanufakturan system set production schedule based on forecasting needs in the future. Though no one can predict the future will come for sure even though he had a perfect understanding of the past and has a keen instinct for trends in the market. Production based on predictions for the future in the traditional system have a greater risk of loss due to over production rather than production based on actual demand. Hence comes the idea of using flexible strategies, short product life time, and able to minimize the time of production (manufacturing lead time) and distribution (ordering leads time) which is the Just In Time, which produces only when there is demand. A production process will produce only when signaled by the next process. As a result, waste can be removed on a large scale, in the form of improved quality and lower production costs. Both of those make the company more cooperative. Just In Time main goal is to improve the company's profitability and competitive position achieved through cost control efforts, improving quality, and improving delivery performance.
II. Purpose The purpose of writing this paper is to determine what is the terms and basic concepts of the application of the Just In Time (JIT) system. It also to know what is the main goal of the implementation of JIT systems in a company.
DISCUSSION
I. Just In Time Just In Time is a manufacturing philosophy that has important implications in cost management. The basic idea of Just In Time is very simple, the production only done if there is demand (full system) or in other words to produce things requested, at the request and for the quantity demanded. The basic principle of Just In Time is an increase in the company's ability to continuously respond to changes in the waste minimization. The companies increased attention to the potential benefits of: 1. Creating purchase orders that are smaller and more frequent. 2. Rebuilding relationships with suppliers. Both of the above related to an increased interest in purchasing the system on time (Just In Time). Just In Time Purchasing is the purchase of goods or materials so the delivery properly precedes demand or use. In an extreme lack of supplies (goods to be sold to a retailer, raw materials work in process or finished goods to a producer) which were stored. Companies that use the purchase of Just In Time normally emphasize the hidden costs associated when holding high inventory levels. These hidden costs include the amount of storage space and a larger number of defects is quite large.
II. Definition of Just In Time Just In Time is a whole philosophy of operations management in which all resources, including raw materials and spare parts, personnel, and facilities used to the extent needed. The goal is to raise productivity and lessen waste. Just In Time is based on the concept of sustainable production and flow of each part of the production process requires collaboration with other components. Direct labor in the Just In Time strengthen with extension responsibilities that contribute to labor costs, space and production time waste cutting. Just- in-time production methods requiring no raw material inventory because raw materials and spare parts to the plant is scheduled to arrive from suppliers only when they need it. In the broadest sense, JIT is a philosophy that focuses on timely events required by other internal segments within an organization. JIT has four main aspects as follows: 1. All activities which are not value added to a product or service should be eliminated. Activities that do not have the value-added increase unnecessary costs, such as inventory as much as possible to zero. 2. There is commitment to constantly improve the quality. So that the damaged and defective products as much as possible become zero, does not require the time and cost to rework a defective product, and can increase the buyer/customers satisfaction. 3. Always strived continuous improvement to improve the efficiency of the activities. 4. Emphasizing on streamlining activities and increasing understanding of the value-added activities. JIT can be applied in various corporate functional areas such as purchasing, production, distribution, administration and so on.
III. Basic Concepts of Just In Time Systems Just In Time production system was originally developed and promoted by the Toyota Motor Corporation in Japan. This strategy was later widely adopted by many Japanese firms, especially After the oil crisis in 1973. The main purpose of the implementation of Just In Time production system is to reduce production costs and increase the productivity of the total industry as a whole by eliminating waste on a continuous basis. The goal of the production Just In Time (JIT) strategy is the reduction of costs and increase the turnover of capital flows (capital turnover ratio) by eliminating any waste in the industrial system. JIT should be viewed as a broader than just an inventory control program. JIT is a philosophy that focuses on efforts to produce products in an amount corresponding to the needs of the customer, at the right place and time.
IV. Just In Time (JIT) Philosophy In simple way, the philosophy of JIT is "eliminate all forms of waste", and the way to achieve it is by making continuous improvement. Waste is defined as any activity that does not add value to the product, or all of the production elements that only increase costs without adding value. One method of the JIT system to reduce waste as goods awaiting is using the MFO (Multi Function Operator) the incorporation of multiple processes to solidify job efficiency. The largest component of waste is waste caused by excessive inventory. The main functions of inventory is as a support between production and the market, in the sense that if the market demand arrives soaring highly and production capacity is not sufficient, then the demand can still be met using existing inventory. But this excessive inventories result in a hidden problem, one of which is the high lead time or the time needed to produce the finished product. Therefore, by reducing the amount of inventory, the problem that is hidden can be seen and solved. There are two things in the waste removal process, among others: 1. Efficiency is only successful if the production cost is reduced. 2. Improving efficiency should be done completely and gradually. From the statement above it appears that the goal of the production strategy of Just In Time (JIT) is the reduction of costs and increase the turnover of capital flows (capital turnover ratio) by eliminating any waste in the industrial system. Under the JIT philosophy, every material, machinery and equipment, human resources, capital, information, management, processes, etc. that do not add value to the product called waste. Value-added products, is the key word in the JIT. Basically the JIT production system has six basic objectives as follows: a. Integrate and optimize every step in the manufacturing process. b. Produce quality products in order to fulfill customer desires. c. Lowering the cost of manufacturing continuously d. Only produce based on customer demand. e. Developing manufacturing flexibility. f. Maintaining a strong commitment to working with suppliers and customers. JIT approach to Total Quality Control (TQC) aims to develop an attitude that is based on three main principles, that are: 1. The first principle: defect-free output is more important than the output itself. 2. The second principle: defects, errors, damage, congestion, etc. can be prevented. 3. The third principle: prevention is cheaper than reworking.
V. Basic Principles of Just In Time To apply the JIT method there are eight basic principles that should be considered in determining the production system strategies, those are: 1. Doing Production in accordance with the order of the Master Production Schedule New manufacturing system will be operated to produce ascertained wait after a certain amount of incoming orders. The ultimate goal to produce finished goods on time and to the extent of the amount that want to be consumed only (Just in Time), for it would result in the production process as many times as needed and immediately sent to customers who need the product in order to avoid the stock as well as to reduce the holding cost.
2. Production is carried out in a number of lots (Lot Size) that are small to avoid complex planning and lead time as well as in the production of large quantities. Flexibility of production activities will be done, because it is easier to make adjustments in the production plan especially against changes in market demand. 3. Eliminate Waste Waste must be eliminated in every area of existing operations. All use of input resources (materials, energy, machinery or working hours, etc.) should not exceed the minimum limit necessary to achieve the production target. 4. Continuous product flow improvements The main purpose is to eliminate processes that cause bottlenecks and all unproductive conditions (idle, delay, material handling, etc.) that can hinder the smooth flow of production. 5. Product Quality Perfection Product quality is the goal of the Just in Time production system application. Here always strived to achieve a state of "Zero Defect" by total control in every step of the process. All forms of deviation must be identified and corrected as early as possible. 6. Respect to People With the Just in Time production system method every worker will be given a full opportunity and authority to govern and make decisions whether a stream of operation should be continued or terminated because of serious problems encountered in a particular work station. 7. Seek to Eliminate Contigencies Inventories that the basic idea are expected to anticipate the fluctuating demand and any unexpected conditions, it will turn into waste if not used immediately. Similarly, recruitment of labor in large numbers in an uncontrolled manner as commonly encountered in the project activity will lead to waste if not used in time. Therefore, in planning and scheduling of production must be carefully designed and controlled. Any form that gives the impression of uncertainty must be eliminated and should be included in the consideration and forecasting formulation models. The seven principles of the implementation of Just in Time production system above is not a firm commitment that is applied in the short term, but it must be built on an ongoing basis and the commitment of all parties in the long run. In the short term, there is the possibility of application of Just in Time production system will only add to the cost of production following the consequences of the process of formation of a learning curve. In addition to the basic principle of just in time, here is the order of application of the just in time technique: Apply 5S basis of improvement; Basic improvement in the workplace is 5S concept that consists of Seiri (choosing), Seiton (arrangement), Seiso (Cleaning), Seiketsu (Consolidation), and Shitsuke (Habits). Implementation of a single production cut to achieve line balancing. Implementation of the production of small lot size and the improvement of methods of preparation. Implementation of operating standard Lancer production assembling products according to the speed of the sale Autonomation ("jidoka") The use of kanban cards.
VI. Benefits of JIT JIT is not just a method of inventory control, but also the production system of interrelated production system with all functions and activities. JIT has many benefits such as: 1. Reduced warehouse space for storage of goods. 2. Reducing setup time and production schedule delays. 3. Reducing waste items damaged and defective items with the detection of errors directly at the source. 4. The proper use of machines and facilities. 5. Creating a better relationship with suppliers. 6. Better plant layout. 7. Quality control in the process.
VII. Relationship between JIT and TQM To implement JIT is necessary to the overall total quality system in the organization. JIT requires all departments to respond to its needs. When implementing JIT production department, but the organization as a whole is not pursuing TQM, the production department personnel will face a major obstacle. Besides JIT also requires changes, so often arise rejection of the department have the money committed to change. Continuous improvement (Kaizen) is always in conjunction with the Total Quality Management (TQM). Even before the TQM philosophy is done or before the quality system can be implemented in a company then this philosophy will not be able to be implemented so that this continuous improvements (Just in time) is a business that adheres to the philosophy of TQM itself. So that Kaizen can also be a unified comprehensive and integrated view. Kaizen is a Japanese term in a language that can be interpreted as continuous improvement. Kaizen is a unified comprehensive and integrated view that includes: 1. Customer-oriented. 2. Overall quality control 3. Robotic 4. Cluster quality control 5. Suggestions system 6. Automation 7. Discipline at the workplace 8. Overall productivity maintenance 9. Kanban 10. Perfection of quality improvement 11. Timely 12. Flawless 13. Small groups activities 14. Working relationship with manjer and employees 15. New product development Kaizen has entered into the spirit of continuous improvement and sustainable based on the spirit, this day should be more than yesterday and tomorrow should be better than today, there should be no day without any improvement.
VIII. Purchasing with the JIT concept Purchasing with JIT concept is a scheduling system procurement in a way such that it can be done quickly to meet the demand for delivery or use. Purchases with JIT concept can reduce the time and costs associated with purchasing activities by: 1. Reducing the number of suppliers so that companies can reduce the resources expended in negotiations with the suppliers. 2. Reduce or eliminate the time and cost of negotiating with suppliers. 3. Having a buyer or customer with the established purchase program. 4. Eliminate or reduce activities and costs that are not value-added. 5. Reduce the time and cost for quality inspection programs.
IX. Production using JIT concept JIT production is a production scheduling system of components or products on time, quality, and amount as required by the next stage of production or according to customer demand. JIT production can reduce the time and cost of production by means of: 1. Reduce or eliminate work in process products in each workstation or stages of product processing (zero inventory concept). 2. Reduce or eliminate the "Lead Time" (waiting time) production (concept of zero wait time). 3. Continually seek to reduce setup cost machines at each stage of processing products (workstation). 4. Emphasizing on streamlining product processing so that the activity is not value-added production can be eliminated.
Companies using JIT production can increase efficiency in the areas of: 1. Manufacturing lead time (waiting time) 2. Inventories of materials, goods in process and finished products 3. Switching time 4. Direct labor and indirect labor 5. Factory rooms 6. Cost of quality 7. Purchases of materials The application of JIT production can have an influence on the cost and management accounting systems in several ways as follows: 1. Direct traceability number of costs can be increased. 2. Eliminating or reducing the cost (cost pools) for indirect activity. 3. Reducing the frequency of the calculation and reporting of information excess labor costs and factory overhead individually. 4. Reduce detail and information recorded in the work tickets.
X. Inventory using Just In Time concept Just In Time is based on the concept of sustainable production and flow of each part of the production process requires collaboration with other components. Direct labor in the Just In Time strengthened by the expansion of responsibilities that contribute to waste cutting labor costs, space and production time. Manufacturing companies keep three kinds of inventory: raw materials, work in process, and finished goods. Supplies are designed to act as a buffer so that the activities of companies are expected to go smoothly despite the supplier fails to delivery or if a department is not able to operate for some time because of something or other. Supplies are designed to act as a buffer so that the activities of companies are expected to go smoothly despite the supplier fails to delivery or if a department is not able to operate for some time because of something or other. However, storage of supplies that are certainly costly. System Just In Time is an attempt to reduce or eliminate the supply. Companies that adopt the system Just In Time to the production process must necessarily redesign plant facilities and the events that trigger the process. Production based on predictions for the future in the traditional system have a greater risk of loss due to over production rather than production based on actual demand. Hence comes the idea of Just In Time, which produce if there is demand. A production process will produce only when signaled by the next process. As a result, waste can be eliminated on a large scale, in the form of improved quality and lower production costs. Both of these companies make more cooperative. Just In Time main goal is to improve the company's profitability and competitive position achieved through cost control efforts, improving quality, and improving delivery performance.
XI. JIT manufacturing and Product Costing JIT manufacturing using a more focused approach than that found in traditional manufacturing. The use of JIT manufacturing system is having an impact on: 1. Improving Traceability costs. 2. Improving the accuracy of product costing. 3. Reducing the need for allocation of cost center service (department services) 4. Changing behavior and the relative importance of direct labor costs. 5. Affect the pricing system and the order cost.
JIT manufacturing Compared with traditional manufacturing JIT manufacturing is a demand pull system (Demand-Pull). JIT manufacturing goal is to produce only if the product is needed and only for the number of requests the buyer (customer). Some of the differences between JIT manufacturing with traditional manufacturing include: No. JIT TRADITIONAL 1 2 3 4 5 6
Pull-through System Inventory isnt significant Manufacturing Cells Interdisciplinary Employee Skills Quality Control (TQC) Decentralization Service Push-through System Inventory is Significant Departmental Structure Specialization employee skills Acceptable quality level (AQL) Centralization Service
XII. JIT and Overhead Costs Traceability In a JIT environment, some overhead activities that were used together for more than one product line can now be traced directly to a single product. Manufacturing shaped cells, interdisciplinary labor, decentralized services and activities are the main characteristics of JIT.
XIII. Effect of JIT on Stock Assessment One of the first accounting problems that can be eliminated with the use of JIT manufacturing is the need to determine the cost of the product in order to inventory valuation. If there is inventory, the inventory should be assessed, and the assessment to follow certain rules for financial reporting purposes. In the JIT, inventory attempt to near zero (or at least not at a level that is not significant), thus becoming irrelevant inventory valuation for financial reporting purposes. In JIT, where Principal pricing products just to satisfy managerial purposes. Managers require accurate product cost information to make various decision, for example: a. determining the selling price based on cost-plus, b. cost trend analysis, c. product line profitability analysis, d. comparison with the cost of competitors, e. decision to buy or by company itself, and so on.
XIV. Effect of JIT on the Ordering Cost of Goods In the application of JIT system for the determination of the ordering cost. First, companies should separate business between the business that the nature is repetitive and between that are special orders. Furthermore, the manufacturing cells can be established for business repeatedly. By reorganizing the layout of manufacturing, the order does not require the most attention in classifying the cost of production. This is because the costs can be grouped on a cellular level. anyway, because the lot size is very small now, it is not practical to arrange the order cost card for each order. Then the order will be using the properties of the system cost.
XV. Determination of Cost Process and JIT In the process method, the cost per unit calculation would be more complicated because of the existance of work-in-process products. By using JIT, zero inventory applied, so that an equivalent unit calculation is not needed, and do not need to calculate the cost of the previous period. JIT is significantly lead to simplification.
Conclusion
In simple, the philosophy of JIT is "eliminate all forms of waste", and the way to achieve it is by doing contious improvement. Waste is defined as any activity that does not add value to the product, or all of the production elements that only increase costs without adding value. From the above explanation can be concluded that the goal of the Just In Time (JIT) production strategy is the reduction of costs and increase the flow of capital turnover (capital turnover ratio) by eliminating any waste in the industrial system. JIT should be viewed as a broader than just an inventory control program. JIT is a philosophy that focuses on efforts to produce products in an amount corresponding to the needs of the customer, at the right place and time. The main goal of JIT is to eliminate waste through continuous improvement. Under the JIT philosophy, every material, machinery and equipment, human resources, capital, information, management, processes, etc. that do not add value to the product called waste. Value-added products, is the key word in the JIT.
References
Schonberger, R.J, Just In Time Production System: Replacing Complexity with Simplicity in Manufacturing Management, Industrial Engineering, vol. 16 no. 10, 1984. Mulyadi, Akuntansi Manajemen, Ed. 5, Jakarta : Salemba Empat, 1999. http://en.wikipedia.org/wiki/Just_in_time_(business) http://en.wikipedia.org/wiki/Kanban http://pakguruonline.pendidikan.net/mpmbs4.html
Family Ownership and The Entrenchment Effect On Intellectual Capital Utilization: A Study of High-Technology Companies in Indonesia Dealing With The ASEAN Economic Community (AEC)
Family Ownership and The Entrenchment Effect On Intellectual Capital Utilization: A Study of High-Technology Companies in Indonesia Dealing With The ASEAN Economic Community (AEC)
PMP Exam Prep: Master the Latest Techniques and Trends with this In-depth Project Management Professional Guide: Study Guide | Real-life PMP Questions and Detailed Explanation | 200+ Questions and Answers