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

Question 1

Discuss process flexibility and its importance to the JIT environment.

Answer 1

Process flexibility is desirable so the company can react swiftly to changes in the volume and mix of their products. To achieve this, operators and machinery must be flexible, and the system must be configured to be changed over quickly from one product to another.

Question 2

Define quality at the source.

Answer 2

Quality at the source means doing it right the first time and, if something does go wrong, stopping the process and fixing it immediately. People become their own inspectors, personally responsible for the quality of what they produce.

Question 3

Suppliers benefit from partnering with their customers with:

A) less long- term security
B) less competitive as a JIT supplier
C) reduction in planning ability
D) more competitive as a JIT supplier

Answer 3

D

Question 4

A company produces a line of golf putters composed of three models. The demand for model A is 500 per month, for B is 400 and for C is 300. What would be the mixed model sequence if some of each were made each day?

Question 5

Questions to be answered in a JIT environment include:

A) What must we get?
B) What do we have?
C) What are we going to make?
D) all of the above

Question 6

Production problems can include:

A) quality problems
B) machine downtime
C) both A and B
D) neither A nor B

Question 7

The benefits to the buyer of partnering with suppliers include:

A) reduction in the need for inbound inspections
B) JIT delivers
C) the ability to supply the quality needed all the time
D) all of the above

Question 8

The JIT system:

A) works to reduce lead times
B) does not require a stable system
C) does not require time fences
D) are not based on lead times

Question 9

A company decides to establish and EOQ for an item. The annual demand is 400,000 units each costing $8 to run, setup costs are $32 , and inventory carrying costs are 20%. Calculate the EOQ in units.

Question 10

The developers of the JIT concepts utilized a simple card system called ________.

A) ishikawa
B) time fences
C) coding
D) kanban

Question 11

What are the major elements or characteristics of a JIT environment. Discuss.

Question 12

The following MPS summary scheduled is leveled for capacity. Using the following table, level the schedule for material as well.

Question 13

A company decides to establish and EOQ for an item. The annual demand is 400,000 units each costing $8 to run, setup costs are $32 , and inventory carrying costs are 20%. Calculate the number of orders per year.

Question 14

A company decides to establish and EOQ for an item. The annual demand is 400,000 units each costing $8 to run, setup costs are $32 , and inventory carrying costs are 20%. Calculate the cost or ordering, cost of carrying inventory, and total cost.

Question 15

Discuss what constitutes value to the end user?

Question 16

Supplier selection should ensure the supplier has:

A) sincerity
B) stable management
C) effective quality systems
D) all of the above

Question 17

Alternatives to cards for indicating production and movement of materials include:

A) designated storage space
B) color coding of containers
C) computer systems
D) all of the above

Question 18

Key factors in supplier partnering include:

A) long- term commitment and trust
B) trust and shared vision
C) long- term commitment, trust, and shared vision
D) long- term commitment and shared vision

Question 19

Discuss total employee involvement in JIT and the changing role of top management.

Question 20

Mixed- model scheduling means:

A) the company doesn't switch model production frequently
B) the scheduled is leveled for capacity and material
C) the company makes only one product per day
D) inventories are at a maximum

Question 21

The pull system starts at the beginning of the line and pulls products from the preceeding operation as needed.

Question 22

For a process to continue to produce the required quality, machinery must be maintained in excellent condition.

Question 23

A successful JIT environment can be achieved without the cooperation and involvement of everyone in the organization.

Question 24

The major effect that JIT has on forecasting is increasing lead time.

Question 25

JIT has evolved from lean production concepts over the last several years.

Question 26

The emphasis in JIT is on achieving the plan - no more, no less.

Question 27

MRP is often called a push system meaning that the material needs are calculated ahead of time.

Question 28

Uniform plant loading means that the work done at each workstation should take about the same time.

Question 29

MRP plans the material flow based on the bill of material, lead times, and available inventory.

Question 30

If good schedules are to be maintained and a company is to develop a JIT environment, it is vital to have good, reliable suppliers.