The workforce is cross-trained to allow flexibility in cell operation and scheduling. This is in contrast to starting jobs into production when orders are received or materials are received, and then trying to adjust schedules through production to maintain manpower and equipment productivity while meeting shipping requirements. When designs and production volumes permit, Kanban systems are used. Storage space for standard components is limited to a number of standard containers. When a container is withdrawn for use in the next operation, an order is automatically generated to make another container of components.
Scrap wastes labor and materials.
Catching quality problems as early as possible eliminates the wasted effort spent on defective materials. Autonomous defect control is used to stop production when a defect is found so that the problem can be corrected before additional effort and materials are wasted. If inventories are low, there is less opportunity for product becoming obsolete before it is shipped. In small batch operations and administrative processes, it is frequently easier to quantify cycle time accurately than it is to measure defects. The customer doesn't want to and generally doesn't pay for it.