BrightClean manufactures and supplies cleaning products to industrial clients, including large factories, hospitals and schools. The company recently adopted a just-in-time (JIT) stock management system to improve efficiency and reduce costs. With JIT, raw materials are delivered only when needed and production schedules are closely aligned with client orders. This approach has significantly reduced stockholding costs and improved cash flow
However, JIT has introduced significant challenges, particularly for BrightClean’s employees. The system relies heavily on punctual supplier deliveries to avoid disruptions. When delays occur, production schedules are thrown off, creating intense pressure on employees to meet tight deadlines. Workers in the packaging department, for instance, have reported being asked to work overtime at short notice to compensate for missed supplier deliveries
This increased pressure has led to conflicts between management and employees, as well as within teams. For example, production staff have criticised managers for not providing sufficient warning about potential delays, while warehouse employees feel unfairly blamed when materials are unavailable. A recent attempt to mediate a dispute about overtime requirements failed because employees felt that their concerns about workload were not taken seriously
Despite these challenges, BrightClean’s management remains committed to JIT due to its financial benefits. The company is now considering whether a just-in-case (JIC) stock management system, which involves holding buffer stock, could reduce disruptions. However, switching to JIC would increase storage costs and tie up more working capital in inventory
In response to employee concerns, the HR department has introduced feedback sessions, but participation has been low, with employees doubting that their input will lead to meaningful changes. Management is also exploring enhanced training programmes and improved communication with suppliers to reduce delays and rebuild trust with the workforce
Table 1: BrightClean – Key metrics (2023 vs 2024)
Metric | 2023 | 2024 |
Stockholding costs ($ million) | 2.5 | 2.0 |
Production delays (days) | 15 | 5 |
Customer complaints (per year) | 120 | 60 |
Employee turnover rate (%) | 18 | 15 |
Table 2: BrightClean – HR metrics
Metric | 2023 value | 2024 target |
Employee turnover rate (%) | 18 | 15 |
Average employee overtime (hours) | 12 | 8 |
Employee absenteeism rate (%) | 5 | 3 |
Participation in feedback sessions (%) | 30 | 50 |
Job satisfaction score (/100) | 65 | 75 |