Flexible Facilities and Multi-skilled Workforce
As we have discussed before, firms that produce the same product repeatedly, can benefit by following JIT production systems. Since the process of production is repetitive, movement of materials can be minimized by placing the equipment in cells (a cell is a grouping of several types of machines in which each machine performs a single operation repeatedly) instead of keeping them in functional departments. Such an arrangement reduces the need for materials handling equipment, thereby reducing material-handling costs. Such flexible facilities improve the speed of the production thereby allowing quick deliveries.
In a JIT production system, workers must be capable of performing more than one operation. The entire workforce is trained continuously (at regular intervals) to develop a variety of skills to serve any function the firm requires. Firms can develop flexible workforces through cross-training. A worker is trained to perform several operations rather than being limited to a single operation assigned to him. Cross-training of the workforce and establishing U-form cells makes the production process more flexible.
Arranging facilities in U-form and processing production activities in small lot sizes makes it easy for the firm to identify the defects that occur at any stage of the production process. The causes of defects can also be identified and corrected easily. When a defective item is found, the JIT system stops the production process to correct the defect, instead of continuing to produce defective items and then trying to rework them. If any work center causes a defect in the product, then all work centers downstream automatically stop operations and help solve the problem.
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