Gaining Time: Implementing of Synchronous Manufacturing, JIT Inventory Management, and MRP in Manufacturing Facilities

4/20/23 9:31 AM

Manufacturing facilities have a complex set of operations that require precise coordination to optimize efficiency and productivity. Synchronous manufacturing, just-in-time (JIT) inventory management, and material requirement planning (MRP) are three critical elements that can help streamline production processes, minimize waste, and maximize profitability. In this blog, we will delve into the details of these three concepts, their benefits, and how they can be implemented in manufacturing facilities.

Synchronous Manufacturing

Synchronous manufacturing, also known as synchronized manufacturing, is a production strategy that emphasizes coordination and communication between all departments and processes within a manufacturing facility. This strategy aims to minimize delays, reduce waste, and improve overall efficiency by synchronizing all aspects of the production process.

In synchronous manufacturing, the focus is on identifying and eliminating bottlenecks in the production process. By reducing or eliminating these bottlenecks, production can flow smoothly, and there is no backlog of work. This ensures that all processes are running at their maximum capacity, which results in faster turnaround times and increased output.

One of the most significant benefits of synchronous manufacturing is improved communication between departments. In a synchronous manufacturing environment, all departments work together to ensure that each process is completed in a timely manner. This ensures that there are no delays in the production process, which can be costly in terms of time and money.

Just-In-Time (JIT) Inventory Management

Just-in-time (JIT) inventory management is a system that aims to reduce inventory holding costs by producing or acquiring products just in time for delivery to customers. JIT aims to minimize inventory levels to the lowest possible level, which reduces the need for warehousing and storage space, reduces the risk of inventory obsolescence, and lowers the overall cost of goods sold.

JIT inventory management works on the principle that inventory is waste. The less inventory that is held, the less money is tied up in inventory, and the less waste there is. JIT aims to produce or acquire only the quantity of products that are required to fulfill customer demand. This eliminates the need for excess inventory, which reduces the cost of storing, managing, and disposing of inventory.

The key benefit of JIT inventory management is that it allows manufacturers to respond quickly to changes in customer demand. By producing or acquiring products just in time for delivery to customers, manufacturers can ensure that they are only producing what is required, which minimizes the risk of overproduction and underproduction.

Material Requirement Planning (MRP)

Material Requirement Planning (MRP) is a computer-based inventory management system that calculates the amount of raw materials required for production based on demand forecasts. MRP is designed to ensure that the right materials are available at the right time, in the right quantities, and at the lowest possible cost.

MRP works by analyzing the production schedule and the inventory levels of raw materials to determine the optimal time to order new materials. The system takes into account lead times for delivery, production time, and other factors that can affect the availability of raw materials. By analyzing this data, MRP can determine the optimal time to order new materials to ensure that they are available when they are needed.

The key benefit of MRP is that it allows manufacturers to optimize inventory levels. By calculating the amount of raw materials required for production based on demand forecasts, MRP can ensure that manufacturers have the right materials available when they are needed. This eliminates the risk of stockouts, reduces the cost of carrying excess inventory, and ensures that production processes can run smoothly.

Implementing Synchronous Manufacturing, JIT, and MRP

Implementing synchronous manufacturing, JIT, and MRP requires careful planning and coordination between different departments and stakeholders within the manufacturing facility. The following are some steps that can be taken to implement these processes effectively:

1. Develop a detailed plan: Developing a plan that outlines the specific steps involved in implementing synchronous manufacturing, JIT, and MRP is essential. This plan should include timelines, resources needed, and specific goals for each process.

2. Assess the current state: Conduct a thorough assessment of the current state of the facility's manufacturing processes, inventory management systems, and production cycle. Identify the strengths, weaknesses, and areas that need improvement.

3. Identify areas for improvement: Based on the assessment, identify the areas that can be improved through the implementation of synchronous manufacturing, JIT, and MRP. Determine how these systems can be integrated and synchronized to achieve the desired outcomes.

4. Train employees: Train employees on the new systems, processes, and tools. Provide training on the importance of waste reduction, quality improvement, and customer satisfaction. Providing training to staff on the new processes and technologies involved in synchronous manufacturing, JIT, and MRP is crucial. This training should include information on the benefits of these processes, as well as how to use any new software or tools involved.

5. Implement the systems: Implement the systems in a phased approach, starting with the most critical areas. Monitor the progress and adjust the implementation plan as needed.

6. Measure and analyze results: Measure the results of the implementation and analyze the data to determine the effectiveness of the new systems. Use the data to identify areas for further improvement and to make adjustments to the systems as needed.

7. Continuous improvement: Implement a continuous improvement process to ensure that the new systems are continuously optimized for maximum efficiency, quality, and customer satisfaction.


The manufacturing industry can greatly benefit from the implementation of Synchronous Manufacturing, Just-In-Time (JIT), and Material Requirements Planning (MRP) systems. These methodologies can help to reduce waste, increase efficiency, and improve overall production processes. While each system has its unique approach, they all share a common goal of minimizing inventory and increasing responsiveness to customer demand. With proper planning and execution, these systems can be successfully implemented in manufacturing facilities of all sizes, resulting in significant improvements in productivity and profitability.

Topics: JIT, MRP, planning, Inventory Management, Efficiency, Improvement, Synchronous Manufacturing


No video selected

Select a video type in the sidebar.

Download the APS Shootout Results


PlanetTogether APS: A GPS System for your Supply Chain - See Video

Recent Posts

Posts by Topic

see all
Download Free eBook
Download Free APS Implementation Guide
Download Free ERP Performance Review