---
title: "Japanese approach: JIT and kanban"
subject: "Industrial Engineering and Management"
chapter: 5
key: "semester_6/industrial_engineering_and_management:japanese-approach-jit-kanban-system"
source: https://www.bctengineer.com/q/semester_6/industrial_engineering_and_management/japanese-approach-jit-kanban-system
site: BCT Engineering
---

# Japanese approach: JIT and kanban

Industrial Engineering and Management · Chapter 5: Material Requirement Planning (MRP I and MRP II)

- Asked in: year not given, 5 marks
- Video: [What is Kanban? Kanban Visual Systems Explained in 4 stages Easily.](https://www.youtube.com/watch?v=zG0wBJQJaK8) — Academic Gain Tutorials
- Answer checked by Claude Opus 5.5 (high effort) on 2026-10-14
- Page: https://www.bctengineer.com/q/semester_6/industrial_engineering_and_management/japanese-approach-jit-kanban-system
- Whole chapter: https://www.bctengineer.com/md/semester_6/industrial_engineering_and_management/chapter-5

## Question

Explain the Japanese approach to material planning (Just-in-Time and kanban). Describe how a two-card kanban system works.

## Short answer

The Japanese approach (Toyota Production System) uses Just-in-Time: produce only what, when, and quantity needed, pulling material based on actual consumption. A two-card kanban system uses production kanban to authorize production and withdrawal kanban to move containers. When a container is used, its withdrawal kanban triggers replenishment.

## Answer

The Japanese approach, developed by Taiichi Ohno at Toyota, is the **Toyota Production System**. Its aim is to produce only what is needed, when it is needed, in the quantity needed (**Just-in-Time, JIT**), with the elimination of waste (*muda*).

#### Main elements
- **Pull system:** production starts only when the next process asks for parts, whereas MRP "pushes" parts according to a forecast schedule.
- **Small lots and short set-up times (SMED).**
- **Levelled production (heijunka)** and uniform loading.
- **Elimination of seven wastes:** overproduction, waiting, transport, over-processing, inventory, motion, defects.
- **Total quality control and jidoka (stop on defect), multi-skilled workers, supplier partnership, U-shaped cells.**

#### Kanban (card) system
**Kanban** means signboard or card. Two kinds are used:
- **Production kanban:** authorises the process to produce a container of parts.
- **Withdrawal (move) kanban:** authorises the next process to take a container from the preceding store.

```text
 Process A ---> [Store A] ---> Process B
   ^   production    |  withdrawal    |
   |   kanban        |  kanban        |
   +---<-------------+-----<----------+
```

Working:
1. Process B uses a container of parts; its withdrawal kanban goes to the store of A and a full container is taken.
2. The production kanban that was on that container is freed and returned to Process A.
3. Process A produces one container to replace it.

The number of kanbans is $N = \dfrac{D\,(T_w + T_p)(1+\alpha)}{C}$ (D demand rate, $T_w$ waiting, $T_p$ processing time, $C$ container size, $\alpha$ safety factor). Fewer cards means less inventory.

## Check yourself

The answer's key points as multiple-choice questions, with the correct option and why.

1. What is the aim of the Toyota Production System (JIT)?
   A. Maintain large buffer stocks
   B. Produce only what is needed, when needed, in the quantity needed, eliminating waste
   C. Produce to forecast in large batches
   D. Maximise machine utilisation at all times
   Answer: B. JIT avoids overproduction and waste (muda) by producing only to demand. (Key point: JIT aim)

2. What distinguishes a pull system from MRP's push approach?
   A. Production is based on a forecast schedule
   B. Parts are pushed to the next stage regardless of use
   C. Production starts only when the next process asks for parts
   D. Orders are released by the computer on fixed dates
   Answer: C. In pull, downstream consumption triggers upstream production; MRP pushes by schedule. (Key point: Pull vs push)

3. What does the withdrawal (move) kanban authorise?
   A. The preceding process to produce a container
   B. The next process to take a container from the preceding store
   C. The supplier to raise prices
   D. The inspector to stop the line
   Answer: B. Withdrawal kanban lets the next process take a container; the production kanban authorises production. (Key point: Kanban types)

4. In the two-card system, what happens after a full container is taken from store A?
   A. The production kanban on it returns to process A, which makes one container to replace it
   B. Process A stops permanently
   C. Process B produces the replacement
   D. Both kanbans are destroyed
   Answer: A. The freed production kanban goes back to A, authorising replacement of exactly one container. (Key point: Kanban cycle)

## Related in Industrial Engineering and Management

- [MRP compared with JIT](https://www.bctengineer.com/question.md?key=semester_6%2Findustrial_engineering_and_management%3Amrp-versus-jit-comparison) — Industrial Engineering and Management, chapter 5

## Related in other subjects

- [Just in time (JIT)](https://www.bctengineer.com/question.md?key=semester_7%2Fict_project_management%3Ajit) — ICT Project Management, chapter 10
- [Power system planning and grid integration](https://www.bctengineer.com/question.md?key=semester_8%2Fpower_plant_design%3Aplanning-deregulated-grid-integration) — Power Plant Design, chapter 2
- [Time cost trade-off and steps in planning](https://www.bctengineer.com/question.md?key=semester_8%2Fconstruction_management%3Atcto-steps-planning) — Construction Management, chapter 2
- [Material handling system and its usefulness](https://www.bctengineer.com/question.md?key=semester_8%2Fconstruction_management%3Amaterial-handling-system) — Construction Management, chapter 6, asked 4×