Just-in-Time Production: Unlocking the Secrets of Toyota's Legendary EfficiencyWhen people first heard of Toyota's approach, "Just-in-Time" was misunderstood as a simple inventory reduction program. In reality, it is one of the core pillars of the Toyota Production System (TPS), designed to create
one-piece flow, expose hidden problems, and eliminate waste across the entire value stream.
Just-in-Time Production takes you behind the scenes of Toyota's revolutionary system, showing how the company emerged stronger than competitors after the 1970 oil crisis and became a global benchmark in manufacturing excellence. Learn why Western automakers misunderstood JIT—and how Lean Thinking, as popularized by James P. Womack, revealed the true power of connecting the whole value chain to customer demand.
Inside this book, you'll explore:
- The myths and realities of "Just-in-Time" and why zero inventory is not the goal
- How to implement heijunka, takt time, pull systems, and continuous flow in manufacturing
- The role of buffers and the Andon system in protecting quality and customer satisfaction
- Practical insights on JIT and jidoka, Toyota's two foundational pillars for operational excellence
Whether you are a plant manager, engineer, or lean enthusiast, this book
demystifies the Toyota Production System and provides actionable guidance to implement lean practices that truly work.
Discover how to move beyond theory and achieve
real, measurable improvements in your operations—just as Toyota has done for decades.
Many people believe that just-in-time inventory equals zero inventory. The ideal situation is one-piece flow, which can only be achieved through the use of a manufacturing cell. The inventory buffer exists, but it is rarely used. The Andon system includes a buffer. There is a safeguard in place to protect your customer. There is a buffer to prevent the entire manufacturing line from being shut down to rectify a problem. There is a buffer in place to prevent the breakdown of a vital manufacturing process.
Just-in-time production is a manufacturing system that produces and delivers only what is required, only when it is required, and only in the amount required. The Toyota Production System is built on two pillars: JIT and jidoka. JIT is based on heijunka and consists of three operating elements: the pull system, takt time, and continuous flow.
