Deck 15: Jitlean Production

Question 1

Lean thinking has received considerable attention in the last decade,but tools such as kanbans cannot be used in all production environments.

Answer 1

True

Question 2

The greater the demand,the more kanbans are needed.

Answer 2

True

Question 3

For a kanban system to work properly,demand rates must be relatively stable,and interruptions must be minimized.

Answer 3

True

Question 4

Inflexible or unreliable processes that cause organizations to produce goods before they are required are called:

A)excess motion.
B)inappropriate processes.
C)overproduction.
D)defects.

Question 5

The cards employed in a two-card kanban system are the production card and the move card.

Question 6

Just-in-time production is the same thing as Lean production.

Question 7

One recent development in Lean thinking is the combination of Lean and Six Sigma into Lean Six Sigma,which combines the rigor of statistical analysis and DMAIC approach with Lean's focus on waste reduction.

Question 8

A reduction in inventory levels forces a company to improve manufacturing practices.

Question 9

Which of the following is NOT an element of Lean production?

A)to have only the required inventory when needed
B)to increase queue lengths
C)to improve quality to zero defects
D)to reduce setup times

Question 10

In the kanban formula,the letter T represents the time it takes to empty a box of parts through building product.

Question 11

An increase in the safety factor results in an increase in the amount of inventory in a kanban system.

Question 12

A two-card kanban system is a planning tool that links production and movement of units at two work centers.

Question 13

A pull system is a production system in which actual downstream demand sets off a chain of events that pull material through various steps in the production process.

Question 14

Since a JIT manufacturer has very little inventory,it is vital that all incoming parts receive a thorough inspection.

Question 15

JIT can be used in:

A)repetitive production.
B)job shop production.
C)many service industries.
D)All of these settings are appropriate for JIT.

Question 16

Some companies have found it beneficial to combine the planning capabilities of kanban with the control capabilities of MRP.

Question 17

The just-in-time philosophy applies only to the production floor of a manufacturing company.

Question 18

Companies employing the Lean philosophy use only kanban as a production control method.

Question 19

The forecast for next month is 200 units so the manufacturer gathers materials for this anticipated level of production activity.This is an example of pull production.

Question 20

Transportation is waste according to the Lean philosophy.

Question 21

A(n)________ is a production control approach that uses containers,cards,or visual cues to control production and movement of goods throughout the supply chain.

Question 22

Which of the following statements regarding supply chain synchronization using kanbans is BEST?

A)An interruption in the flow of goods within a supplier's assembly operations will have no effect on final assembly downstream in the supply chain.
B)For the system to work properly,demand rates must be relatively stable and interruptions must be minimized.
C)If final assembly demand doubles,there is no need to change kanban counts at each of the suppliers.
D)Final assembly demand may rise or fall,but the sum of the kanbans among all suppliers in the supply chain will remain constant.

Question 23

Livernonions Industries uses a kanban system to manage production of the BR-549 subassembly.In an eight-hour day they use 900 units and use containers that can hold 30 units each.It takes 120 minutes to fill and move a container of parts to the right place on the BR-549 line that is currently rated at a 15% safety factor.How many production hours of inventory are needed?

A)18.4
B)7)6
C)4)3
D)2)4

Question 24

Scrap or rework are examples of the JIT waste recognized as:

A)defects.
B)inappropriate processing.
C)unnecessary motion.
D)waiting.

Question 25

Olivia has had enough of the theoretical equations and rejects the higher math needed to calculate the number of kanbans for her system.One approach that some organizations take in lieu of the kanban equation is to:

A)start with one kanban and operate as fast as they can with the one,before adding more kanbans to bring them up to speed.
B)start with too many kanbans and gradually reduce them until a problem arises.
C)fully load their system with inventory and produce until they cannot build product.
D)eliminate all inventory from the system and add material and parts until they can fill a customer order.

Question 26

In a two-card kanban system:

A)each box of finished goods has a move card so it can be sent to the next step.
B)each box of raw material has a production card so it can be made into finished goods.
C)a downstream station pulls finished material out of a production area.
D)demand for more raw materials pushes finished goods to the finished goods area.

Question 27

Any activity that does not add value to the good or service in the eyes of the consumer is ________.

Question 28

The analogy of rocks in a river is often used when discussing Lean principles.In the analogy,the rocks represent ________ while the water represents ________.

Question 29

The eighth waste added to Ohno's list of seven wastes is ________.

Question 30

Just-in-time production is also referred to as ________.

Question 31

________ combines the focus on waste reduction with the discipline of define,measure,analyze,improve,and control.

Question 32

A kanban can be:

A)a container.
B)a card.
C)a visual cue.
D)All of these can be kanbans.

Question 33

In the water and rocks analogy for JIT:

A)water represents problems.
B)water represents inventory.
C)rocks represent inventory.
D)water wears away rocks gradually just like continuous improvement programs improve quality.

Question 34

In a two-card kanban system:

A)the production card signals when a move card should be moved to the next process step.
B)the move card signals when a container of parts should be produced.
C)the production card signals when a container that held parts should be returned to inventory.
D)the move card signals when a container of parts should move to the next process step.

Question 35

Lean supply chain management focuses on eliminating waste:

A)in a firm's sourcing and logistics activities.
B)within a firm's internal operations.
C)in flows of information and money among supply chain partners.
D)in all of the above areas.

Question 36

Liversuch Industries uses a kanban system to manage production of the J-15 subassembly.They have an hourly demand for 250 units and use containers that can hold 50 units each.It takes 90 minutes to fill and move a container of parts to the right place on the J-15 line that is currently rated at a 20% safety factor.How many production cards are needed?

A)540
B)100
C)9
D)1)5

Question 37

Under two-card kanban system rules,each box of raw material must have a(n)________,while each box of finished goods must have a(n)________.

Question 38

Livermore Industries uses a kanban system to manage production of the KR-9 subassembly.In a ten-hour day they use 1500 units and use containers that can hold 50 units each.It takes 45 minutes to fill and move a container of parts to the right place on the KR-9 line that is currently rated at a 15% safety factor.How many production cards are needed?

A)3
B)26
C)82
D)155

Question 39

When using MRP and kanban together:

A)the control capabilities of MRP are used instead of those from kanban.
B)the planning capabilities of kanban are used instead of those from MRP.
C)the demand rate should be variable in order to derive the greatest benefit from the MRP portion of the system.
D)the number of kanbans is recalculated from the MRP system's order changes throughout the horizon.

Question 40

In a single-card kanban system:

A)the single card is the production card.
B)the empty container serves as the production card.
C)the single card is the move signal.
D)None of the above is correct in a single-card system.

Question 41

Describe the movements of parts and kanbans in a two-card kanban system.

Question 42

What is the Lean perspective on inventory?

Question 43

Recent developments in Lean thinking have combined these principles with Six Sigma and with supply chain management.Pick either one of these programs and describe its elements.Then provide an example from current business news of an operation or supply chain that has embraced these principles.

Question 44

Provide a definition by description of the Lean philosophy.Where can Lean be deployed?

Question 45

The number of kanbans in a production system is inversely related to the ________.

Question 46

Companies that use MRP and kanban together use the ________ of MRP and the ________ of kanban.

Question 47

Two modules are used to feed the final assembly station on an assembly line.The final assembly station must produce 250 units in an eight-hour day.Each finished unit needs two module As and 3 module Bs.The factory uses a standard sized container that can hold 25 module As or 35 module Bs.It takes 2 hours to fill and move a container of module As but only 90 minutes to fill and move a container of module Bs.If both module assembly processes have safety factors of 15%,how many containers should be used for each? How many hours of demand will this satisfy?

Question 48

What are the consequences of unstable demand and interrupted flows on a supply chain managed with a JIT philosophy?

Question 49

Describe any five of the wastes identified by the JIT philosophy.

Question 50

A manufacturer waits to produce until they have an order from a customer.This type of production system is called ________.

Question 51

Use this material requirements planning record to explain how kanban and MRP can be used together.This plant operates on a 40-hour week,and uses a 10% safety factor on a container size of 20 units with a half-day turnaround time on a container.What features of each system should be used and for what purposes?