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Guide: J

Just-in-Sequence (JIS) in Warehouse Logistics
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Just-in-Sequence (JIS) in Warehouse Logistics

Table of Contents

Just in Sequence (JIS): The synchronized supply chain in detail

Just in Sequence (JIS) is an extension of the Just-in-Time (JIT) concept. While JIT ensures that materials arrive exactly when they are needed, JIS adds another dimension: order. This is particularly crucial in the automotive industry (OEM), where highly individualized variants of a model are produced on an assembly line.

The goal is to supply production without stock. Components such as seats, door panels or cable harnesses are delivered in such a way that the employee on the assembly line removes exactly the part that belongs to the vehicle chassis currently standing in front of him, without any sorting effort.

 

State-of-the-art JIS sequencing center from a bird's eye view, where robots place differently colored car bumpers in the correct order into containers on a conveyor belt that are loaded directly into a truck. An example of automated sequencing and the pearl chain principle in warehouse logistics

 

The pearl chain principle: process flow and data exchange

The core of JIS is the so-called "pearl necklace". The sequence of the vehicles on the assembly line determines the pearl necklace of the supplier parts.

  • The call-off: The OEM sends electronic call-offs (often via EDI/VDA standards) to the supplier or logistics service provider. This often happens only a few hours before installation (the so-called "lead time" or "frozen zone").
  • Picking: In the supplier's warehouse, the parts are not picked in batches, but exactly according to the submitted list and packed into special load carriers (sequence racks).
  • Transport: The truck is loaded in such a way that unloading at the factory gate can take place synchronously with the belt cycle.

An error in the sequence ("sequence break") can lead to an immediate line stoppage. Therefore, the penalties in JIS contracts are extremely high and can quickly amount to several thousand euros per minute of downtime.

Warehouse logistics: From buffer storage to sequencing center

From a warehouse logistics perspective, JIS fundamentally changes the structure of the warehouse. These are rarely classic supply warehouses, but highly dynamic transshipment points.

  • Pick technologies: In order to achieve the zero-defect rate, technologies such as pick-by-light, pick-by-voice or RFID-supported systems are standard. Every move is digitally acknowledged.
  • Layout: The routing is optimized for speed. Supermarket concepts (small parts warehouse directly on the line) or flow racks are often used.
  • Emergency concepts: A JIS warehouse must have safety stocks (safety stock) in order to absorb truck breakdowns or production disruptions for a short time without interrupting the chain.

Role of Contract Logistics and LLPs

In practice, contract logistics providers (3PL) or lead logistics providers (LLP) often take over JIS processing. The OEM outsources the risk and complexity.

The contract logistics company often operates so-called JIS centers or sequencing centers in the immediate vicinity of the plant. Parts from various upstream suppliers arrive here, are unpacked, quality checked, pre-assembled if necessary (value-added services) and then delivered sequenced "to the assembly line". The logistical masterpiece here lies in the synchronization of different flows of goods into a single, harmonious rhythm.

Requirements for the logistics property (JIS hall)

A property used for Just in Sequence differs significantly from a standard logistics warehouse ("Big Box"). Investors and project developers must consider specific criteria here:

  • Location (location, location, location): The property must be in close proximity to the production plant (often < a 10-20 km radius) to ensure short response times. Congestion risks on the connecting route are an exclusion criterion.
  • Doors and deliveries: Since the turnover of goods is extremely high (cross-docking character), JIS halls require an above-average number of loading doors per square metre of hall space (e.g. 1 door per 300-500 m² instead of the usual 800-1,000 m²).
  • Lateral unloading: Special canopies or ground-level gates are often required, as sequence racks are sometimes handled by side unloading (tautliners).
  • Third-party usability: JIS properties are often "single-tenant" properties (tailored to a client). The risk for investors is higher because if the contract is cancelled, the property can be more difficult to re-let due to its specific equipment (many gates, shallower depth).

Profitability and risk management

Why do companies take this risk?

  1. Inventory reduction: The OEM hardly has to provide any storage space, which massively reduces capital commitment.
  2. Variety of variants: Without JIS, today's individualization (thousands of combinations of colors, rims, interior) would not be possible in terms of space in the factory.
  3. Process costs: By  outsourcing to logistics service providers, fixed costs are variable.

However, the risk is shifting strongly to the IT infrastructure and transport routes. An IT failure in the sequencing center is equivalent to a production stop at the plant. Redundant systems are therefore mandatory.

 

An employee in an automotive factory removes a color-matching door panel from a just-in-sequence load carrier that stands directly on the assembly line to install it in a car body. The scene illustrates the seamless integration of logistics into production without intermediate storage

 

FAQ: Frequently Asked Questions about Just in Sequence

Question: What is the exact difference between JIT and JIS?

Answer: JIT delivers the right part at the right time. JIS delivers the right part at the right time in the right order. JIT is suitable for parts of the same type (e.g. screws), JIS for parts with a wide range of variants (e.g. coloured bumpers).

Question: What industries is JIS suitable for?

Answer: Mainly automotive. Increasingly, however, this is also the case in aviation, mechanical engineering and the production of "white goods" (household appliances), provided that assembly line production with high variance is available.

Question: What is the "pearl necklace"?

Answer: The pearl necklace symbolizes the fixed, unchangeable order of the production orders for a defined period of time (e.g. 3-5 days). It is the database for JIS delivery.

Question: What is the typical lead time for JIS?

Answer: That varies a lot. With "Long-Distance JIS" it can take days, for deliveries from a supplier park directly at the factory gate often only 60 to 180 minutes between call-off and installation.

Future Outlook: JIS 4.0

The future of JIS lies in complete transparency. Thanks to IoT sensors on load carriers, OEMs and logistics companies know in real time where each part is located. Autonomous mobile robots (AMRs) are increasingly taking over picking in the sequencing centers in order to further reduce the error rate to zero. In addition, sustainability aspects are becoming increasingly important: JIS transports must be bundled more efficiently in order to avoid empty runs and high emission values due to the high frequency.

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