Deck 21: Just-In-Time and Lean Production

Question 1

The ultimate goal of a lean system is to achieve a balanced,rapid flow of materials through the system.

Answer 1

True

Question 2

A major difference between kanban and MRP in scheduling the products to be built is that kanban is primarily a manual system.

Answer 2

True

Question 3

A benefit of small lot sizes in JIT systems is that each product is produced less frequently.

Answer 3

False

Question 4

JIT refers to a production system in which goods arrive for processing just as the preceding batch is completed.

Question 5

The use of small lot sizes in JIT is in conflict with the EOQ approach.

Question 6

Setup time and cost can often be reduced by the use of group technology.

Question 7

In a JIT environment,anything superfluous is viewed as waste.

Question 8

In a broad sense,JIT is identical to lean production.

Question 9

Waiting time is not considered a waste in the JIT philosophy.

Question 10

A JIT system uses long production runs as this reduces the setup time required.

Question 11

Reductions in setup time are necessary to make a JIT system feasible.

Question 12

Continuous improvement and flexible systems are requirements for successful JIT and lean systems.

Question 13

"Group technology" can be used to reduce setup cost and time in a JIT conversion.

Question 14

JIT was developed at the Ford Motor Company by Henry Ford.

Question 15

The four building blocks of JIT are: product design,process design,personnel/organizational elements,and planning and control.

Question 16

The small lot-sizing policy works well in a situation where both holding costs and setup costs are high.

Question 17

Manufacturing cells are commonly used in JIT systems

Question 18

Flexible systems undermine the goals of JIT and lean systems to have a balanced,rapid flow of products.

Question 19

A benefit of JIT is the flexibility to handle a mix of products within a short time frame.

Question 20

In the JIT philosophy,the smaller the lot size,the better.

Question 21

A fundamental tenet of the JIT philosophy is that workers are assets,not a cost element.

Question 22

"Autonomation" is the JIT/lean tactic of automating the transfer of production between steps in a production process.

Question 23

The purpose of an andon is to provide an immediate visual signal indicating when and where problems are occurring in a process.

Question 24

The JIT philosophy recognizes that a buffer inventory is necessary.

Question 25

In a "pull system," a pile of inventory in front of a workstation indicates problems at that workstation.

Question 26

JIT/lean production systems need to be directed by strong leadership roles based on top-down communication to ensure production schedules are implemented accurately.

Question 27

In the JIT approach,the content,sequence,and timing of employees' work processes are intentionally left flexible to allow for continuous improvement.

Question 28

A JIT/lean system is not effective when the industry consists of a tiered supplier network.

Question 29

JIT purchasing requires frequent bidding for contracts by multiple sources to ensure the buyer of competitive prices.

Question 30

JIT systems typically require that suppliers be able to provide large lots at fairly regular intervals.

Question 31

Kanban is a system of lights used to signal problems or slowdowns in a production process.

Question 32

It is primarily manufacturing personnel that are required to support a JIT system.

Question 33

For JIT/lean companies,certification of suppliers using a system such as ISO 9001 provides a cost effective alternative to having to develop close supplier relationships.

Question 34

A stable,level,mixed product model production schedule is not advantageous or necessary for JIT/lean systems.

Question 35

Manufacturing cells in JIT systems process similar parts for a product.

Question 36

A kanban card is used to signal that work is ready to be moved to the next station.

Question 37

The ideal scheduling for JIT/lean operations follows a push system of planning.

Question 38

The control of the flow of work in JIT systems can be characterized as a backward communication approach.

Question 39

An advantage of JIT cross-trained workers is they can help other workers when bottlenecks occur.

Question 40

JIT/lean systems minimize finished product inventory but have a greater reliance on work-in-process inventory.

Question 41

When contrast with MRP systems,JIT systems:

A)solely focus on the flow of end products.
B)focus on long term production planning.
C)rely on visual or audible signals to trigger production.
D)relies on "pushing" items through stages of production planning.

Question 42

Which of the following is not included in world class manufacturing?

A)just-in-time manufacturing
B)total quality management(TQM)
C)total management control (TMC)
D)total productive maintenance (TPM)
E)total industrial engineering (TIE)

Question 43

In JIT/lean systems "preventive maintenance" is designed to provide a rapid response after a breakdown has occurred to get the equipment back on line as fast as possible.

Question 44

The maximum time allowed at each workstation to complete its set of tasks on a unit is called:

A)unit time
B)takt time
C)flow time
D)JIT time
E)Andon time

Question 45

The JIT/lean approach is best used for custom operations that experience fairly unstable demand.

Question 46

The sole purpose of housekeeping in JIT/lean operations is to enhance safety in the workplace.

Question 47

In relation to lean,it can be difficult for an organization to change its culture within a short time.

Question 48

Underutilization of employee knowledge/skill is considered waste in a lean production environment.

Question 49

The ultimate goal of lean systems is to have:

A)minimal in-process inventories.
B)empowered cross-trained workers.
C)a balanced,rapid flow of materials and products through the system.
D)reduced setup times.
E)small production lot sizes.

Question 50

Which of the following is not an element of the building blocks of JIT/lean operations?

A)High levels of quality in products and processes
B)Highly specialized,narrowly focused,process design
C)A program of continuous improvement
D)Level loading production planning
E)Close supplier relationships

Question 51

Process design can increase production flexibility in a variety of ways.Which of the following is not a technique used for this purpose?

A)Reduce setup time
B)Cross train workers
C)Use a few large machines
D)Use safety stocks
E)Keep some idle capacity

Question 52

Inventory reduction is another aspect of lean that can apply to services.

Question 53

Of the following,which is an obstacle to JIT/lean conversion?

A)Management lacks commitment
B)Resources are allocated to the project
C)Workers are willing to be cooperative
D)Managers shift some responsibility to workers
E)Suppliers accept long-term commitments

Question 54

Which of the following is not considered as increasing value to the customer?

A)quality
B)inventory
C)time
D)cost
E)flexibility

Question 55

In a JIT system,long-term relationships with suppliers are unusual.

Question 56

Which one of the following is not one of the foundational building blocks of JIT?

A)Product design
B)Process design
C)Personnel/organizational elements
D)Planning and controls
E)ERP application software

Question 57

In services,the primary focus of lean systems is the time needed to perform a service.

Question 58

The progress of a plant toward perfection (zero injuries,zero waste/loss/defects/breakdowns,and zero inventories)is measured by ___ technical criteria (called pillars)and ___ managerial criteria(foundations).

A)5,5
B)5,7
C)7,9
D)7,10
E)10,10

Question 59

Which of the following is not considered a type of waste which JIT/lean systems are designed to reduce?

A)Excess inventory
B)Product designs with little potential for recycling
C)Underutilization of employee knowledge and skills
D)Unnecessary transportation/movement of goods
E)Scrap and rework

Question 60

JIT/lean is best suited for a corporate environment of mutual respect and _______.

A)fear
B)compensation
C)training
D)cooperation
E)flexibility

Question 61

A set of tools and methods for reducing setup time developed by Shigeo Shingo is called:

A)enterprise resource planning (ERP).
B)design for manufacturability (DFM).
C)single-minute exchange of die (SMED).
D)group technology.
E)One-at-a-Time

Question 62

In the JIT philosophy,the ideal lot size is:

A)the economic order quantity.
B)the economic run size.
C)one unit.
D)the capacity of the standard container.
E)N = (DT(1 + X))/C.

Question 63

A term that refers to the automatic detection of defects is:

A)poka-yoke.
B)autonomation.
C)jidoka.
D)andon.
E)kanban.

Question 64

Which of the following is not a benefit of small lot sizes in JIT systems?

A)In-process inventory is lowered
B)Fewer production runs are required for each product
C)Holding costs are reduced
D)Less space is required for storage
E)Increased visibility of problems

Question 65

Which of the following is not true about worker/management roles and relations for JIT?

A)Stress on workers is reduced by requiring less of them.
B)Workers are considered a key asset of a JIT system.
C)Two-way communication between workers and management is encouraged.
D)Employees are empowered in selecting and using methods.
E)Workers receive non-manufacturing support

Question 66

The basic objective for operating with low inventories in JIT systems is:

A)to uncover recurring problems in production processes.
B)inventory investment must be saved.
C)major problems must be uncovered.
D)major problems must have been solved.
E)inventories must be reduced rapidly.

Question 67

Which of the following is a benefit of small lot sizes in JIT systems?

A)Quicker response to changing customer demands.
B)No safety stock is required.
C)Work-in-process inventory is eliminated.
D)Inventory planning models are not required.
E)Long production runs increase efficiency

Question 68

Which one of the following is not affiliated with product design to support JIT/lean operations?

A)Concurrent engineering
B)Design for manufacturing and assembly
C)Product quality
D)Material requirements planning (MRP)
E)Quality function deployment (QFD)to capture the "voice" of customers

Question 69

Which of the following is not associated with converting to cellular layouts?

A)Determining a family of products to group together
B)Designing the process for the product family
C)Balancing the cell
D)Reducing the variety of end products produced
E)Determining the capacity of the cell

Question 70

Which of the following does not contribute to reduced setup time and cost?

A)Grouping internal and external setup activities
B)Train operators and standardize the setup procedure
C)Streamline setup procedures for products
D)Use of multipurpose equipment or attachments
E)Use of group technology

Question 71

Which of the following is not an important element of personnel and organization for JIT?

A)Cross-trained workers
B)Authoritative command and control style leadership
C)Support from non-manufacturing personnel such as marketing and finance
D)Participation in kaizen (continuous improvement)
E)Workers as assets

Question 72

Continuous improvement (Kaizen)is based on all the tenets except:

A)involvement of everyone in the organization.
B)applied throughout the organization.
C)learning by doing.
D)direct observation and data collection.
E)rapid,major breakthroughs in improvement.

Question 73

The term used in Japan that refers to quality at the source,meaning stopping to fix problems to avoid passing defective products on to the next workstation is:

A)poka-yoke.
B)autonomation.
C)jidoka.
D)andon.
E)kanban.

Question 74

The technique intended to increase functional communications,reduce the need for changes and speed up the design process is called:

A)design for manufacturing and assembly (DFM and DFA).
B)quality function deployment (QFD).
C)concurrent engineering.
D)group technology.
E)takt time reduction.

Question 75

Which of the following are benefits of level capacity loading?

A)Maximizes work-in-process inventory
B)Minimizes time to setup for different products
C)Limits the flexibility to meet customer demand
D)Minimizes work-in-process inventory
E)Maximizes work-in-process inventory

Question 76

Material requirements planning (MRP)is an example of a(n):

A)push system.
B)pull system.
C)backward communications approach.
D)inventory accumulation approach.
E)forecasting process for finished goods

Question 77

Which of the following is not a goal of JIT/lean production?

A)System flexibility
B)Elimination of waste
C)Continuous improvement
D)Preventative maintenance
E)Elimination of disruptions

Question 78

Which of the following are potentially negative aspects of cross-functionally trained workers?

A)Less motivated workforce based on reduced decision-making authority
B)Less flexibility because workers are less able to assist one another
C)Higher stress levels from added responsibility and a continued push to improve
D)Less flexible system of operation.
E)Cultural shift in the organization is required.

Question 79

The control of the flow of work in JIT systems is best characterized as a:

A)push system.
B)pull system.
C)backward communications approach
D)inventory accumulation approach
E)neutral system

Question 80

JIT philosophy tries to eliminate work-in-process inventory because:

A)of the savings in capital requirements.
B)inventory covers up recurring problems.
C)it frees up space for kanban storage bins.
D)dependency on suppliers should be increased.
E)it initiates shorter production runs.