Optimising manufacturing processes is currently a priority for the industrial sector. The automotive industry, in particular, is facing the challenge of so-called mass personalisation. The need to deliver thousands of product variants on a single assembly line is forcing a change in the logistics paradigm. Traditional methods based on high inventory levels are becoming economically inefficient.
The solution is the Just-in-Sequence (JIS) logistics model. This is the highest level of sophistication in supply chain management. This concept goes beyond the standard timeliness framework known from the Just-in-Time (JIT) system. In the JIS model, the key parameter is sequence synchronisation. Components arrive on the production line in exactly the same sequence in which they are assembled in subsequent product units.
This mechanism allows for the complete elimination of storage buffers on the assembly line. This reduces operating costs and frees up capital tied up in inventory. However, it requires absolute precision at the interface between production and transport.
The theory of sequencing is clear, but its implementation depends on the human factor and the reliability of the fleet.
At Jasek Transport, we specialise in servicing critical links in the supply chain. We offer dedicated transport solutions that guarantee the stability of our partners’ production processes. For us, punctuality is not a promise, but a measurable KPI.
In this article, we analyse aspects of sequential logistics and explain how to effectively manage the supply stream in a JIS system.
What is Just-in-Sequence (JIS)? Definition and mechanism of operation
Just-in-Sequence (JIS) is a logistics model in which the delivery of components is closely synchronised with the assembly process. In this system, the supplier not only ensures timeliness (as in Just-in-Time). They also take on an additional task: arranging the goods in a specific, predetermined order.
This mechanism is best illustrated by the car manufacturing process. Imagine an assembly line. Three car bodies are moving along it: the first requires leather seats, the second fabric seats, and the third sports bucket seats.
In the traditional model, the warehouse worker would have to search for the right seats on the shelves. In the JIS model, the supplier packs the seats into a transport container in exactly this sequence: leather, fabric, bucket. The production line worker takes the item out of the container and installs it. It fits perfectly into the vehicle currently being serviced. There is no room for decision-making or searching. It is pure execution of the plan.
The key concept here is the ‘pearl chain’. This is an industry term for an unbreakable sequence of data on planned production. The manufacturer (OEM) sends this sequence to the supplier a few days in advance. From that moment on, the sequence is sacrosanct. No link in the chain can change its position. This forces the logistics operator to maintain absolute discipline. A mistake in loading a single pallet disrupts the sequence for the entire production shift.
What is the difference between JIS and JIT?
These terms are often used interchangeably, which is a mistake. Just-in-Sequence (JIS) is an evolution of the Just-in-Time (JIT) model, not its synonym. Both systems have a common goal: to reduce inventory. However, they differ in their level of precision and the way goods are prepared.
The Just-in-Time model focuses on time. It tells the carrier: ‘Deliver the goods exactly when they are needed so that they do not remain in the warehouse.’ In this model, the supplier can bring a pallet containing 50 identical mirrors. The factory worker takes them from the pallet in any order because they are all the same.
The Just-in-Sequence model adds the criterion of variability. It says: ‘Deliver the goods on time and in the order in which the cars enter the line.’ Here, the pallet contains 50 mirrors, but each one may be different (black, silver, with or without a camera). The driver essentially brings a ready-made production plan, not just parts.
The basic difference concerns the operation of the assembly line. In JIT, the employee often has to assemble the goods (select the appropriate model from the container). In JIS, this stage disappears – the employee reaches for the part instinctively ‘blindly’, confident that it is the right one.
How does sequential logistics work?
JIS logistics is a precise mechanism. There is no room for improvisation. The entire operation begins long before the driver starts the truck engine. The process can be divided into three critical stages. Each of them must work flawlessly.
Stage 1: production plan and data flow
It all starts in the IT system. The manufacturer (e.g. a car factory) sets the production plan for the coming days. This list is ‘frozen’ – from this point on, the order of cars on the assembly line will not change.
This rigid plan, called Pearl Chain, is sent to the component supplier. This is done automatically via EDI (Electronic Data Interchange) or ERP systems. There are no phone calls or emails involved. The digital signal contains precise information: ‘In 4 hours, I need 50 cockpits in the following order: black, grey, black with navigation…’.
Stage 2: picking and packing process
Upon receiving the signal, the supplier takes action. This is where the goods are physically arranged. Depending on the specific nature of the factory, two methods are used:
Pick-to-sequence: the warehouse worker retrieves the finished items from the shelves in the order dictated by the system.
Sequential production: machines produce components immediately in the correct order (common, for example, in the production of seats).
The completed parts are placed in specialised transport containers (e.g. gitterboxes or dedicated racks). The arrangement in the container mirrors the assembly process. The first component to be removed from the container must be the first one needed on the line.
Stage 3: transport and ‘warehouse on wheels’
This is where the logistics operator comes in. The loaded lorry becomes a mobile warehouse. The journey time is calculated down to the minute. The driver has a strict time slot for unloading.
In the JIS system, the vehicle does not wait in a buffer car park. It drives directly to the gate (dock) assigned to a specific section of the production line, where unloading takes place instantly. Containers with goods go straight onto the conveyor belt, often in an automated system. If the lorry is late, the line stops because the factory does not have a stock of these specific parts.
What are the advantages of Just-in-Sequence transport?
Why are manufacturers increasingly abandoning traditional deliveries in favour of sequencing? The answer boils down to three hard economic benefits. Implementing the Just-in-Sequence model with an experienced logistics operator means:
No storage costs for the recipient
With the JIS model, you eliminate the need to build and maintain large storage facilities at the factory. Energy costs, forklift operation and warehouse staff costs are eliminated. Your company only pays for transport and current production, converting high fixed costs into variable costs.
No inventory
Inventory is frozen capital. Parts sitting on shelves are money that is not working. Sequential logistics eliminates this problem. Goods arrive and are used immediately. This means you do not tie up cash in inventory, you do not risk parts becoming obsolete, and you drastically improve your company’s cash flow.
Delivering modules directly to the assembly line
In this system, the lorry is no longer just a means of transport. It becomes a mobile part of your production line. The modules, assembled and arranged in sequence, are transferred from the lorry directly into the hands of the assemblers. We skip the stages of receiving goods into stock, sorting and internal logistics. This is the maximum simplification of the process, which translates into speed and efficiency of production.
The most common mistakes in organising JIS transport – where does the risk lie?
The sequential model offers huge financial benefits, but it does not forgive amateurism. The margin for error in this system is zero. Any disruption in the supply chain results in an immediate halt to the customer’s production line. This is the worst-case scenario for any logistics specialist.
Despite this, many companies make repeated mistakes at the planning stage. Here are the pitfalls that most often destroy the effectiveness of JIS implementations:
Choosing a random carrier
The biggest mistake is looking for savings on freight. Ordering sequential transports on transport exchanges is like playing Russian roulette. A driver picked at random does not know the notification procedures, does not understand the concept of a time window and does not feel the pressure that weighs on this load. JIS logistics requires a dedicated fleet and regular drivers who know the route by heart.
Lack of digital integration
Relying on e-mails and phone calls for communication in the 21st century is a mistake. In the JIS system, the flow of information must be faster than the flow of goods. The lack of automatic data exchange (EDI) between the manufacturer’s system and the logistics operator leads to delays. The carrier needs to know about a change in sequence in a fraction of a second, not an hour later.
Overly optimistic time planning
Paper schedules often do not take into account the reality of the road. Traffic jams, accidents and ITD checks are a daily occurrence. Planning a route ‘to the limit’ without allowing for a safety margin results in delays. A professional plan always includes contingency scenarios.
In a separate article, we list the most common mistakes in implementing JIS logistics and suggest how to avoid them.
What do you gain by entrusting JIS transport to Jasek Transport?
The decision to implement sequential deliveries is one thing. Finding a carrier that can handle this rigour is another. Choosing an operator with experience in JIS (such as Jasek Transport) brings your company specific operational benefits. Here’s why working with experts is safer than looking for savings on the stock market.
Guaranteed production continuity
This is the most important argument. There is no buffer warehouse in JIS. If the vehicle does not arrive, the line stops. By working with us, you buy peace of mind. We understand what contractual penalties for line stoppage are. That is why we only delegate dedicated vehicles and proven drivers to handle JIS. We do not risk your contract by outsourcing the load to random subcontractors.
Full process transparency
For logistics, the worst thing is not knowing. In sequential transport, you need to know where each part is. We offer full system integration. Our vehicles are visible in your system. Thanks to telematics and GPS, you can see the estimated time of arrival (ETA) down to the minute. If something unexpected happens on the route, you know about it immediately, which gives you time to react.
Flexibility in unexpected situations
Production plans are often subject to change. Machine breakdowns, strikes, sudden increases in orders – these are everyday occurrences. As a family business, we make decisions faster than corporate giants. Do you need an additional vehicle on Sunday? Do you need to change the sequence during transport? We are a partner who adapts to your rhythm, not just rigid procedures.
Elimination of unloading errors
Our drivers are not just ‘wheel holders’. They are trained in notification procedures and dock handling in automotive factories. They know how to position the vehicle under the ramp so that the automatic unloading systems work properly. We relieve your warehouse staff of the need to ‘babysit’ the driver. The vehicle arrives, unloads and leaves – quickly and smoothly.
How is transport priced in the Just-in-Sequence model?
Pricing and costs of sequential logistics are governed by different rules than standard road transport. In the case of regular ‘general cargo’ or full truckload (FTL), you usually pay per kilometre travelled or per pallet space. In the JIS model, this approach is insufficient. Here, you are not just buying transport, but a guarantee of process continuity.
The billing model in JIS is usually based on a project contract. The final price is the result of several key factors that you need to consider when budgeting:
The cost of dedicated rolling stock (exclusivity)
This is the most important difference. A vehicle serving the JIS line usually cannot take other loads ‘on the way back’ because it must be ready for the next sequence. You pay for exclusivity. The vehicle is assigned to your project 24 hours a day. The rate must cover the fact that the vehicle is ‘blocked’ for other orders, even when it is standing idle and waiting to be loaded.
Handling loops and empty containers
JIS transport is rarely one-way. It is usually a closed loop. The driver takes full modules to the factory and returns with empty containers (gitterboxes, racks).
Therefore, the price often includes a so-called ‘round trip’. The cost of transporting empty packaging is an integral part of the process, not an addition. Cost efficiency here depends on how densely the empty containers can be packed on the return trip.
Driver availability and working hours
Production lines often operate in three shifts, including weekends. This requires hiring double, and sometimes triple, the number of drivers for one vehicle in order to comply with working time regulations. The pricing must take into account the labour costs necessary to maintain 24/7 operational continuity.
Technology and risk
The freight rate in JIS also includes a ‘safety net’. This covers the costs of IT system integration (so that you can see the vehicle in your system) and higher OCP insurance. The carrier assumes a huge risk of contractual penalties for line stoppages, which must be reflected in the price of the service.
Sequential transport (JIS) – summary
Just-in-Sequence logistics is no longer the domain of only the largest automotive companies. Today, it is the standard for any manufacturer who wants to compete on quality and flexibility, not just price. The transition from a warehouse model to sequential deliveries is a milestone in business optimisation. It allows you to free up frozen capital, reclaim production space and eliminate assembly errors.
However, implementing this system requires a change in thinking about transport. A lorry is no longer just a vehicle transporting goods from point A to point B. It becomes a mobile link in the production line. In this system, the reliability of the logistics operator is as important as the efficiency of the machines in the factory.
At Jasek Transport, we understand this responsibility. We know that behind every order there is a production schedule that must not be disrupted. We have our own fleet, modern technology and a team that can work under time pressure. If you are looking for a partner who will turn logistical risk into your operational advantage, we are at your disposal.
