5 Logistics Challenges That Can Disrupt Just-in-Time Manufacturing — And How to Stay Ahead
Just-in-time manufacturing depends on precise, reliable logistics. Discover five key challenges that can disrupt production and practical ways manufacturers can build greater supply chain resilience.
Editorial Desk
Aug 19, 2026
8 min read
What happens when a critical component arrives 24 hours late?
For a manufacturer operating with traditional inventory levels, it may be an inconvenience. For a just-in-time (JIT) manufacturing operation, it can create a much bigger problem.
JIT is built around delivering what is needed, when it is needed and in the quantity required. The approach helps manufacturers reduce unnecessary inventory, waste and lead times.
But there is a trade-off: the leaner the inventory buffer, the more important reliable logistics become.
The UK Government's 2026 Global Supply Chains: A Foresight Report on Risk and Resilience highlights the increasing importance of understanding supply-chain vulnerabilities and building resilience into global supply networks.
So, where can JIT logistics go wrong?
Transport Delays and Unpredictable Transit Times
A shipment doesn't have to disappear to disrupt production. Sometimes, it is simply late.
A supplier may dispatch on schedule, but port congestion, carrier changes, weather, transhipment delays or inland transport issues can extend the actual delivery time.
For an international component, the journey may involve:
Supplier
Collection
Export
Port/Airport
International Freight
UK Border
Customs
Inland Transport
Factory
Every stage introduces another potential point of disruption.
For JIT, the key question isn't simply “Where is my shipment?” It is: “Will it arrive before production needs it?”
Manufacturers should therefore monitor critical shipments against planned milestones and have escalation procedures when a consignment moves outside its expected schedule. Related reading: Steps to Implement JIT Logistics Strategies.
Customs and Documentation Problems
For UK manufacturers importing components, customs is part of the logistics lead time — not a separate activity that happens after transport.
HMRC's guidance requires import declarations to contain accurate information, including details such as commodity codes, customs procedure codes and consignment references.
Supporting documentation is equally important. HMRC states that clearance can take longer where documents are invalid or rejected, or where information requires validation by another government department.
For a JIT manufacturer, this creates an important distinction: a customs issue isn't just a customs issue. It can become a production issue.
A delayed shipment discovered too late is another.
If a manufacturer learns on the morning of production that a critical component will not arrive, there may be few options remaining.
Earlier visibility gives the business more time to respond. It may be possible to contact the supplier, change the delivery arrangement, explore alternative transport or adjust production sequencing.
This is why JIT logistics needs to go beyond basic tracking.
The important question is not just where the shipment is, but whether it is still on schedule.
Manufacturers should monitor key milestones from supplier dispatch through to final delivery and establish clear procedures for handling exceptions.
Supplier and Logistics Coordination Gaps
JIT manufacturing is fundamentally a coordination exercise.
The supplier has a production schedule. The carrier has a collection schedule. The freight forwarder manages bookings and transport. Customs has its own processes. The warehouse has receiving requirements. The factory has a production schedule.
If these timelines aren't aligned, disruption can occur even when every individual party is performing its role.
A shipment arriving “on time” isn't necessarily successful if it arrives outside the manufacturer's required delivery window.
For JIT, the objective should be: right component + right quantity + right location + right time.
That requires communication between procurement, suppliers, logistics providers, customs teams, warehouse staff and production planners. An experienced freight forwarder can act as the coordinating link across those parties.
Inventory That Is Too Lean
Perhaps the biggest strategic challenge is finding the right balance between efficiency and resilience.
JIT does not necessarily mean manufacturers should hold zero safety stock. Nor does resilience mean filling warehouses with excess inventory.
The better question is: which components can safely operate on a lean model, and which require additional protection?
A component may warrant greater contingency planning if it is:
Critical to production
Difficult to substitute
Sourced from a single supplier
Imported over a long lead time
Vulnerable to transport or geopolitical disruption
Expensive or difficult to replace quickly
The UK's Supply Chain Resilience Framework encourages businesses to identify vulnerabilities and dependencies when developing resilience strategies.
The practical answer may therefore be JIT where possible, resilience where necessary.
How Can Manufacturers Make JIT Logistics More Resilient?
Manufacturers don't necessarily need to abandon JIT. They need better control over the logistics supporting it.
Identify Critical Components
Determine which parts could actually interrupt production if delayed.
Map the Complete Logistics Lead Time
Include supplier preparation, collection, international freight, customs and final delivery — not just the quoted transport time.
Prepare Customs Documentation Early
Check commodity classification, documentation and declaration requirements before dispatch.
Monitor Exceptions, Not Just Locations
Knowing where cargo is matters. Knowing whether it is still on schedule matters more.
Create Contingency Options
For critical components, consider alternative routes, transport modes, suppliers or targeted inventory buffers.
JIT Doesn't Mean Zero Risk. It Means Better Control.
Just-in-time manufacturing can reduce unnecessary inventory and improve production flow, but it also increases the importance of dependable logistics.
When components cross international borders, freight, customs, shipment visibility and final delivery all become part of the production equation.
The strongest JIT operations aren't necessarily those holding the least inventory. They're the ones with better visibility, stronger coordination and a clear response when something changes.
At Clarusto Logistics, we support businesses with international freight forwarding, customs clearance, warehousing and transport coordination — helping critical cargo move efficiently from supplier to production site.
JIT logistics coordinates the movement of materials so they arrive at the required location, in the required quantity and at the required time to support production.
Why can logistics delays affect JIT manufacturing?
Because JIT operates with leaner inventory, there may be less stock available to absorb an unexpected delay. Transport, customs, supplier and delivery disruptions can therefore have a greater operational impact.
How can customs disrupt JIT manufacturing?
Incorrect or incomplete customs information or supporting documentation can delay the clearance and release of imported components.
Does JIT mean manufacturers should have no safety stock?
No. Manufacturers can use targeted buffers for components where the potential cost of production disruption is greater than the cost of holding additional inventory.
How can manufacturers improve JIT resilience?
Better shipment visibility, accurate customs preparation, supplier coordination, alternative logistics options and targeted contingency planning can all help make JIT supply chains more resilient.
