Deck 15: A: Just-In-Time and Lean Production

Question 1

Manufacturing cells are commonly used in JIT systems

Answer 1

True

Question 2

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

Answer 2

True

Question 3

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

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

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

Question 6

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

Question 7

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

Question 8

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

Question 9

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

Question 10

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

Question 11

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

Question 12

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

Question 13

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

Question 14

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

Question 15

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

Question 16

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

Question 17

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

Question 18

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

Question 19

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

Question 20

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

Question 21

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

Question 22

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

Question 23

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

Question 24

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

Question 25

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

Question 26

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 27

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

Question 28

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

Question 29

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

Question 30

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 31

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

Question 32

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

Question 33

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

Question 34

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

Question 35

The JIT philosophy recognizes that a buffer inventory is necessary.

Question 36

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

Question 37

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

Question 38

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

Question 39

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

Question 40

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

Question 41

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 42

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 43

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 44

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 45

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 46

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 47

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 48

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 49

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.
E) all of the choices are true.

Question 50

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 51

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 52

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

Question 53

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 54

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 55

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) none of the choices.

Question 56

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

Question 57

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

Question 58

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) All of the choices are benefits.

Question 59

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 60

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 61

A kanban card is used to signal that:

A) work is needed from the preceding station.
B) work is ready to be moved to the next station.
C) a worker has run out of parts.
D) a machine has broken down.
E) a machine is ready for preventive maintenance.

Question 62

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) All of the choices are true.

Question 63

Which of the following is not affiliated with the implementation of JIT/lean systems?

A) Inventories are reduced
B) Space requirements are reduced
C) Quality is increased
D) Fewer orders from suppliers need to be processed
E) Closer relationships with suppliers

Question 64

Which of the following is not a characteristic of preventive maintenance in JIT systems?

A) Maintaining equipment in good operating condition
B) Replacing parts before rather than after they fail
C) Training workers to do certain repairs themselves
D) Eliminating supplies of spare parts
E) All of the choices are true

Question 65

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) All of the choices are elements

Question 66

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) none of the choices.

Question 67

A visual tool consisting of process flow diagrams that includes information flows and the activity times refers to:

A) value stream mapping.
B) kanban control.
C) the 5S principles.
D) push analysis.
E) pull analysis.

Question 68

Which of the following are benefits of level capacity loading?
I)Minimizes work-in-process inventory
II)Minimizes time to setup for different products
III)Maintains flexibility to meet customer demand

A) I only
B) II only
C) III only
D) I and III
E) I, II, and III

Question 69

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) all of the choices are true.

Question 70

A system of lights used at each workstation to signal problems or slowdowns is a(n):

A) jidoka.
B) automation.
C) andon.
D) pull system.
E) kanban.

Question 71

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

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

Question 72

With regard to suppliers,JIT systems typically require:

A) delivery of large lots at regular intervals.
B) buyer inspection of goods and materials.
C) multiple sources from which to purchase.
D) long-term relationships and commitments.
E) focusing on the lowest price possible.

Question 73

The Four Star Publishing Company uses sixty reams of paper each hour at one of its high speed printing stations.The waiting time for a standard container,which holds 15 reams of paper,averages forty minutes.If management has decided to use three containers,what safety factor was applied?

Question 74

Which of the following contributes to the competitive advantage enjoyed by firms using JIT/lean production?
I)Lower processing costs
II)Fewer employees
III)Fewer defectives
IV)Greater flexibility.

A) I, II, and III only
B) II, III, and IV only
C) I and IV only
D) I, III, and IV only
E) I, II, III, and IV

Question 75

Which of the following is a characteristic of the JIT philosophy?

A) Inventories become a valued asset.
B) Few, large deliveries of orders from suppliers.
C) Suppliers become partners.
D) Queues of WIP inventory are a necessary investment.
E) All of the choices are correct.

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) none of the choices.

Question 77

Which of the following are potentially negative aspects of cross-functionally trained workers?
I)Less motivated workforce based on reduced decision making authority
II)Less flexibility because workers are less able to assist one another
III)Higher stress levels from added responsibility and a continued push to improve

A) I and III
B) I and II
C) III only
D) II and III
E) I, II, and III

Question 78

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 79

With regard to suppliers,JIT systems typically involve:

A) delivery of large lots on short notice.
B) the highest quality at the lowest price.
C) collaborating to ensure on-time delivery.
D) multiple suppliers to purchase from.
E) all of the choices.

Question 80

The All Seasonings Company uses 3,200 glass jars at one of its jar-filling workstations each eight hours of production.The waiting time for a standard container,which holds 90 jars,averages 45 minutes.If management uses a safety factor of twenty percent,how many containers should be used?