Deck 7: Just-In-Time and Lean Systems

Question 1

The philosophy of JIT

A)Originated in Japan
B)Was operational at Henry Ford's complex in 1920's
C)Is a production planning system
D)Has received little attention in the US
E)Focuses on direct control of worker activities by management

Answer 1

Originated in Japan

Question 2

The manufacturing process in JIT starts with the

A)final assembly schedule
B)schedules for individual machines
C)vendor deliveries
D)prioritization of lots
E)forward scheduling

Answer 2

final assembly schedule

Question 3

Kaizen is a Japanese term referring to __________________________.

A)just-in-time production
B)continuous improvement
C)employee involvement
D)concurrent engineering
E)simplicity

Answer 3

continuous improvement

Question 4

An employee who will not help a customer because "it is not my job" violates the JIT belief of

A)Simplicity
B)A broad view of operations
C)Continuous improvement
D)Visibility
E)Pull production

Question 5

Which of the following is characteristic of the JIT philosophy?

A)Inventories are an asset
B)Lot sizes are optimized by formula
C)Tolerate some scrap
D)Elimination of waste
E)Rigidity

Question 6

JIT is often mistakenly assumed to

A)refer to the final assembly schedule only
B)dictate the product standards specification
C)refer to only just-in-time manufacturing
D)be a core element of ISO 9000 requirements
E)be driven by the finance department long range spending plan

Question 7

In the broad view of the organization everyone should have

A)the same job duration
B)the same retirement plan
C)the same job description
D)the same view of serving the customer
E)a narrow view of the organization that includes only their assigned tasks

Question 8

The central belief of the JIT philosophy is

A)Quality must be emphasized
B)Use of Kanban
C)Elimination of waste
D)Minimize inventory
E)Save money

Question 9

JIT flexibility refers to

A)ability to modify sales figures
B)correct the bull whip effect
C)increase or decrease supplier deliveries on short notice
D)workers being able to perform many different tasks
E)managers being able to shift positions easy

Question 10

Being able to keep costs low while changing the volume of production is an example of

A)Simplicity
B)Flexibility
C)Visibility
D)Continuous improvement
E)Total quality management

Question 11

JIT was based on the need for

A)survival
B)waste elimination
C)better working conditions
D)consistent application of policies
E)consistent supplier performance

Question 12

JIT is applies to

A)only the manufacturing organization
B)only the service organization
C)both the manufacturing and service organizations
D)only the production portion of manufacturing and service organizations
E)all of the organization except the marketing division

Question 13

For the current month using JIT

A)The same amount of each product is produced in the same order each day
B)Production matches that of last month
C)Lot sizes are varied week-to-week
D)Production differs greatly from day to day
E)Production is primarily for next month's sales

Question 14

An improvement tool that utilizes cross-functional teams to plan and deliver improvements to specific processes during two- or three-day marathon sessions is called a ___________________.

A)kanban blitz
B)cross-functional blitz
C)short-term blitz
D)JIT blitz
E)kaizen blitz

Question 15

JIT considers waste anything that

A)Fits in a waste basket
B)Reduces production capacity
C)Has been discarded
D)Cannot be recycled
E)Does not add value

Question 16

Three basic elements work together to complete a JIT system: just-in-time manufacturing,total quality management,and

A)Quality circles
B)Pull production
C)Minimizing inventory
D)Respect for people
E)Full utilization of capacity

Question 17

JIT can be traced back to the early 1900's but no one can argue that the philosophy gained worldwide prominence

A)at the close of WWII
B)in the 1950s
C)in the 1960s
D)in the 1970s
E)in the 1980s

Question 18

The broad view of JIT is now often termed __________________________.

A)vendor-managed inventory
B)business process reengineering
C)lean production
D)cycle time management
E)e-distribution

Question 19

By focusing on __________ processes,JIT is able to achieve high-volume production of high-quality,low-cost products.

A)downstream
B)upstream
C)change-over
D)gateway
E)value-added

Question 20

Beliefs that help define the JIT philosophy include all of the following except

A)Simplicity
B)Visibility
C)Flexibility
D)Push production
E)Continuous improvement

Question 21

The number of kanbans or containers needed at a workstation is dependent on all except which of the following?

A)the demand rate
B)the number of workers
C)the size of the container
D)the lead time
E)the safety stock level

Question 22

According to JIT,__________ is carried to cover up a wide variety of problems,such as poor quality,demand uncertainty,and slow delivery.

A)Inventory
B)Excess capacity
C)A group of back-up workers
D)Spare equipment
E)Insurance

Question 23

In JIT the workforce is viewed as

A)another resource to be managed
B)another contractual obligation
C)a long-term asset
D)a short term asset
E)an asset that must be closely managed

Question 24

Unlike JIT traditional quality control systems use

A)quality circles
B)quality plans
C)control charts
D)acceptable quality levels
E)quality applications

Question 25

JIT uses a pull system where communication starts with either the customer or with the _________ work station in the production line.

A)First
B)Bottleneck
C)Dominant
D)Most expensive
E)Last

Question 26

The objective of quality at the source is not only to identify a quality problem,but also to

A)Determine its extent
B)Uncover its root cause
C)Rate its seriousness
D)Place blame
E)Categorize it

Question 27

JIT manufacturing cannot succeed if __________costs are too high.

A)Variable
B)Fixed
C)Set-up
D)Depreciation
E)Marginal

Question 28

JIT is a __________ system.

A)Pull
B)Push
C)Lead time
D)Preventive maintenance
E)Closed

Question 29

JIT believes in developing __________ relationships with suppliers.

A)Long-term
B)Adversarial
C)Arms-length
D)Temporary
E)Distant

Question 30

An important TQM concept is that quality is defined by the

A)Quality control group
B)Marketing department
C)Board of directors
D)Customer
E)Auditors

Question 31

Traditional manufacturing operations are based on the assumption that

A)Overproduction is disastrous
B)Nice guys finish last
C)It is better to anticipate future requirements and plan for them
D)If you manufacture it,demand will increase
E)Inventory has no value

Question 32

In JIT a Kanban card is used to signal

A)The need for more parts
B)A supplier needs assistance
C)A worker is overloaded
D)A machine is ready for preventive maintenance
E)Management is inspecting operations

Question 33

What must happen before it is possible to operate successfully with JIT?

A)Inventory space must be eliminated
B)Inventories must be reduced rapidly
C)Problems must be uncovered
D)Problems must be solved
E)Setup times must be increased

Question 34

The ultimate goal of JIT is to produce products in a lot size of

A)100 or fewer
B)N = (DT(1+X))/C
C)The inverse of the carrying cost
D)One
E)The capacity of the factory

Question 35

JIT considers __________ to be a company's most precious resource.

A)Capital
B)Productive equipment
C)Information
D)People
E)Vision

Question 36

According to JIT,by eliminating inventory we can clearly identify __________ and work on eliminating them.

A)Obsolete products
B)Malfunctioning machines
C)Grievances
D)Product imperfections
E)Problems

Question 37

JIT relies on a ______ that withdraws parts for a previous work cell and moves them to the next.

A)Information technology system
B)coordination system
C)six sigma system
D)quality circle system
E)transportation system

Question 38

__________ are groups of workers who are responsible for every aspect of their business.

A)Focus teams
B)Staff departments
C)Partnerships
D)Self-managed teams
E)Negotiators

Question 39

Without kanbans,the withdrawal and production of materials

A)can continue in a reduced manner
B)will not be well coordinated
C)cannot take place
D)would continue based on historical needs
E)would continue based on forecasted needs

Question 40

With JIT there are two types of Kanban cards,production Kanban and __________ Kanban.

A)Buffer
B)Transaction
C)Withdrawal
D)Logistics
E)Sales

Question 41

According to JIT,workers should perform

A)system specification development
B)as directed by the supervisor
C)routine preventive maintenance activities
D)poka-yoke designs
E)quality program development

Question 42

Small lot production

A)Increases inventory
B)Decreases flexibility
C)Reduces setup
D)Increases excess processing
E)Shortens lead time

Question 43

Regular inspections and maintenance designed to keep a machine operational is __________ maintenance.

A)Preventive
B)Breakdown
C)Unscheduled
D)Emergency
E)Unnecessary

Question 44

It the goal is to reduce the amount of inventory in the system,the number of Kanban cards should

A)Be decreased
B)Be increased
C)Remain the same
D)Be calculated by formula
E)Remain the same,but container size should be increased

Question 45

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

A)Keeping machines operational
B)Regular inspections of machines
C)Workers helping to maintain their own equipment
D)Operating machines properly
E)Perceiving breakdowns as an opportunity for continuous quality improvement

Question 46

One aspect of flexible resources is

A)Use of multifunction workers
B)Relying on special equipment
C)Use of overtime
D)Leasing,rather than buying,equipment
E)Variable work schedules

Question 47

Quality in just-in-time is centered on building quality into the

A)Product
B)Maintenance of equipment
C)Process
D)Distribution system
E)Workforce

Question 48

Just-in-time relies on __________ worker skills,meaning the ability of workers to perform many different tasks on many different machines.

A)Natural
B)Verbal
C)Intuitive
D)Manual
E)Cross functional

Question 49

External setups

A)Are the same as single setup
B)Can be done while the machine is running
C)Are undesirable for small lot production
D)Are often contracted out
E)Are more common than internal setups in traditional manufacturing systems

Question 50

Consider a workstation that can process 4 units per minute.It takes 2 hours to receive an order from the previous station.The container size is 10 units.The factory sets safety stock at 20 percent of demand during lead time.How many kanbans are needed for the workstation?

A)57.6
B)48
C)0.96
D)9.6
E)28.8

Question 51

What is the term that means giving workers authority to stop the production line when quality problems are encountered?

A)Automation
B)Kaizen
C)Muda
D)Poka-yoke
E)Jidoka

Question 52

The system of Kanbans used to coordinate delivery of goods by suppliers can include all of the following except

A)Filled containers delivered by the supplier
B)Purchase approvals by the production manager
C)Mail boxes for each supplier
D)Empty containers with a Kanban
E)Bar-coded Kanbans

Question 53

What is the term for an adjustment of a machine after making one product type so that production can begin for another product type?

A)Level assembly schedule
B)Group technology
C)Setup
D)Cycle time
E)Automation

Question 54

Something you would not expect to see in a just-in-time work environment is

A)Order
B)Clutter
C)Ample space
D)Tools in their place
E)Cleanliness

Question 55

Uniform plant loading involves

A)Large lots produced over several days
B)Making the same mix of products every day in small quantities
C)Large amounts of inventory
D)Making large changes in production to respond to changes in demand
E)Spreading production uniformly over several plants

Question 56

Quality problems in manufacturing can come from many sources,including all of the following except

A)Customer needs are not incorporated into the product design
B)Low quality materials from suppliers
C)Product specifications being ignored
D)Equipment problems from design of the production process
E)Operator error

Question 57

The advantages of cell manufacturing using a U-shaped cell include all of the following except

A)Production efficiency with flexibility to produce a variety of parts
B)Easy reach and flexibility for workers
C)Higher worker satisfaction
D)No special material handling
E)Longer setup times

Question 58

Just-in-time organizations rely on employees to

A)Do what their boss tells them to do
B)Dress differently every day
C)Work together
D)File grievances
E)Be adversarial toward management

Question 59

Consider a workstation that can process 4000 units per hour.It takes 15 minutes to receive an order from the previous station.The container size is 20 units.The factory sets safety stock at 20 percent of demand during lead time.How many kanbans are needed for the workstation?

A)16
B)3600
C)50
D)10
E)60

Question 60

Poka-yoke means

A)Using color coding
B)Foolproofing
C)Using process control charts
D)Preventive maintenance
E)Undercapacity scheduling

Question 61

JIT production workers

A)Keep data to themselves
B)Participate in team problem-solving activities
C)Do not understand data
D)Never use data
E)Rely on others to do data analysis

Question 62

One of the greatest benefits of JIT would be

A)increasing waste and improving responsiveness
B)longer lead times and increased productivity
C)decreased machine utilization and improved quality
D)competing based on schedules
E)eliminating waste,improving responsiveness and competing based on time

Question 63

The benefits of long-term relationships with a small number of suppliers include all of the following except

A)Always getting the lowest price
B)Focus on improving process controls
C)Greater accountability
D)Develop stable delivery schedules
E)Eliminate paperwork

Question 64

In Japan,lifetime employment

A)Is a recent trend
B)Has had little impact
C)Is an ideal that is never achieved
D)Is true for everyone
E)Comprises a relatively small percentage of the total work force today

Question 65

The challenge for service operations is that they have to synchronize their __________ with demand.

A)accounting
B)finance
C)marketing
D)production
E)information systems

Question 66

With JIT a company's relationship with its suppliers includes

A)Competitive bidding
B)Being in partnership with them
C)Buying parts from the cheapest supplier
D)Short-term relationships
E)Having as many suppliers as possible

Question 67

Which of the following is not a good approach for suppliers who are providing JIT services to manufacturers?

A)Use the "push system" for deliveries
B)Locate near their customers
C)Have small warehouses near the manufacturing plant
D)Use standardized containers
E)Join together with other suppliers to help each other make small deliveries

Question 68

JIT production workers are expected to

A)Cover up quality problems
B)Ignore data
C)Take responsibility in getting to the root cause of quality problems
D)Blame problems on someone else
E)Have a poor attitude about quality

Question 69

With regard to suppliers,JIT typically requires

A)Delivery of large lots at regular intervals
B)Buyer inspection of incoming goods and materials
C)Multiple sources from which to purchase
D)Information sharing
E)Buying parts from the cheapest supplier

Question 70

Which of the following is not a role of JIT management?

A)creating a JIT culture
B)cost and information sharing
C)serving as coaches and facilitators
D)developing an incentive system
E)ensuring multifunctional training occurs

Question 71

The role of production employees in JIT includes all of the following except

A)Be actively engaged in improving the production process
B)Monitor quality
C)Record data
D)Follow clearly defined and limiting work rules
E)Act on the information they have

Question 72

JIT considers waste anything that does not add value.

Question 73

In making specific changes to JIT manufacturing,which of the following steps should come first?

A)reduce lot sizes and lead times
B)switch to pull production
C)reorganize workplace
D)reduce setup times
E)implement layout changes

Question 74

Continuous improvement is called kaizen by the Japanese.

Question 75

In a JIT environment,workers need to

A)Protect themselves from their boss's whims
B)Be prepared to be reprimanded
C)Keep their ideas to themselves
D)Always work in pairs
E)Feel secure in their jobs

Question 76

Often the best quality problem resolution solution involves a complex answer as the organization is a complex organization.

Question 77

Which of the following is not a characteristic of bottom-round management?

A)Consensus management by committees or teams
B)Participation in quality circles
C)Decision making starts with discussion at the bottom level
D)Lack of consensus
E)Employees volunteering to help solve quality problems

Question 78

Which of the following is not considered to be a key element of JIT supplier relationships?

A)suppliers viewed as internal factory
B)use of single-source suppliers
C)long-term supplier relationships developed
D)suppliers locate near customer
E)cost and information sharing

Question 79

The broad view of JIT is now often termed lean production or lean systems.

Question 80

An improvement tool that utilizes cross-functional teams to plan and deliver improvements to specific processes during two- or three-day marathon sessions is called a kanban blitz.