Deck 15: Just-In-Time and Lean Production

Question 1

JIT type approaches have many different names. Lean operations is a :

A) JIT approach
B) Non-JIT approach

Answer 1

JIT approach

Question 2

The 'lean' concept has much wider implications for improving operations' performance beyond
planning and control issues.

Answer 2

True

Question 3

Within JIT, process owners are encouraged to assume ownership of their machines and undertake routine maintenance. This is called:

A) Preventative repairs
B) Routine checking
C) Total productive maintenance
D) Maintenance service

Answer 3

Total productive maintenance

Question 4

JIT type approaches have many different names. Buffer inventories is a :

A) JIT approach
B) Non-JIT approach

Question 5

JIT type approaches have many different names. Short cycle time manufacturing is a :

A) JIT approach
B) Non-JIT approach

Question 6

The lean approach aims to:

A) Reduce buffer inventory, but increase safety inventory
B) Reduce the level of inventory
C) Maintain buffer inventory
D) None of the above

Question 7

JIT type approaches have many different names. Stockless production is a :

A) JIT approach
B) Non-JIT approach

Question 8

Which one of the following would be considered a prerequisite for successful lean production?

A) Suppliers in multiple locations.
B) Sophisticated production and materials planning computer systems.
C) Preventive maintenance of equipment.
D) The preparation of a Master Production Schedule.
E) High variety of product range.

Question 9

Is the following statement characteristic of MRP or JIT.Planning and control concepts are only part of a wider philosophy.

A) MRP
B) JIT

Question 10

Is the following statement characteristic of MRP or JIT. Highly dependent on the accuracy of data derived from bills of materials, stock records, etc.

A) Characteristic of MRP
B) Characteristic of JIT

Question 11

The traditional approach sees inventory as a 'blanket of obscurity' that lies over the production
system, preventing problems being noticed.

Question 12

Lean generally has a lower capacity utilisation than a traditional approach to operations.

Question 13

Just-in-time principles, which once were a radical departure from traditional operations practice,
have now themselves become orthodox.

Question 14

In lean it is usual to use one specialist large machine rather than several small machines.

Question 15

The lean approach aims to reduce which of the following?

A) Poor floor layout
B) Rework
C) Work in progress
D) All of the above

Question 16

Producing goods and services exactly when they are needed - not before they are needed, so they wait as inventory, nor after they are needed, so customers have to wait - is called:

A) Precision operations
B) Perfect operations
C) Just-in-time or lean
D) High flexibility

Question 17

The just-in-time approach assumes that each stage in the manufacturing process will place the
parts it produces in an inventory that buffers that stage from the next one downstream in the total
process.

Question 18

JIT type approaches have many different names. High capacity operations are a:

A) JIT approach
B) Non-JIT approach

Question 19

Lean does not require:

A) Customer demands met from production, not inventory
B) Focus on high capacity utilisation
C) Dependable supply parts and reliable equipment
D) disruption in production due to quality errors

Question 20

Is the following statement characteristic of MRP or JIT.Usually needs a complex, centralised, computer-based organisation to support the necessary hardware.

A) MRP
B) JIT

Question 21

What is the term given to the kanban used to signal to a previous stage that material can be withdrawn from inventory and transferred to a specific destination?

A) Customer kanban
B) Production kanban
C) Move or conveyance kanban
D) Vendor kanban

Question 22

Which of the following is NOT true of the 'traditional' view of capacity utilisation?

A) Lower capacity utilisation
B) More production at each stage
C) More stoppages
D) High inventory

Question 23

Which of the following is NOT a type of kanban?

A) Vendor kanban
B) Conveyance kanban
C) Customer kanban
D) Production kanban

Question 24

Which of the following basic working practices is NOT held to be the basic preparation for implementing lean?

A) Outsourcing
B) Total people involvement
C) Development of personnel
D) Quality of working life

Question 25

Which of the following is NOT true of kanban?

A) Parts are always pulled by a succeeding process.
B) No parts are started without a kanban card.
C) The time period should be made shorter.
D) The number of kanbans should remain the same.

Question 26

Which of the following is NOT a visibility measure?

A) SPC charts
B) Demand forecasts
C) Kanbans
D) Coloured lights indicating stoppages

Question 27

Heijunka is the Japanese name for:

A) Continuous improvement
B) Total productive maintenance
C) Levelled scheduling
D) Total people involvement

Question 28

The time taken to change over the process from one activity to the next is defined as:

A) Start-up time
B) Changeover time
C) Set-up time
D) Downtime

Question 29

Kaizen is the Japanese word for:

A) Respect-for-humans
B) Employee involvement
C) Continuous improvement
D) Elimination of waste

Question 30

Depending on the type of kanban being used, the principles applied will vary.

Question 31

Which of the following is NOT a major method of achieving the transfer of internal set-up work to external work?

A) Improving the loading and unloading of new tools.
B) Presetting tools.
C) Investing in fewer large machines.
D) Attaching different tools to a standard fixture.

Question 32

Which of the following basic working practices is NOT held to be the basic preparation for implementing lean?

A) Flexibility
B) High pay
C) Autonomy
D) Discipline

Question 33

Simply shouting 'send some more!' is a verbal form of kanban.

Question 34

Lean tends to involve using:

A) Large machines
B) Multiple-sourcing strategies
C) Few staff
D) Small machines

Question 35

Which of the following is NOT part of the lean philosophy of operations?

A) Continuous improvement
B) Elimination of waste
C) More production at each stage
D) Total people involvement

Question 36

Many companies implementing lean have consistent pay structures that do not differentiate
between full-time staff and hourly rated staff.

Question 37

Kanban is sometimes called the:

A) Invisible conveyor
B) Materials planner
C) Inventory destroyer
D) Signal system

Question 38

Which of the following methods is NOT used to reduce set-up time in the lean approach?

A) The reduction in search for tools and equipment.
B) The practice of set-up routines.
C) The investment in large machinery.
D) The pre-preparation of tasks.