Final Exam- JIT/Lean Production

Question 1

Just-In-Time

Answer 1

a philosophy of manufacturing (and service industries) based on planned elimination of all waste and continuous improvement of productivity; focus on inventory

Question 2

Lean

Answer 2

a philosophy of production that emphasizes the minimization of the amount of all the resources (including time) used in the various activities of an enterprise

Question 3

What does Lean involve?

Answer 3

identifying and eliminating non-value-adding activities in design, production, supply chain management, and dealing with customers; focus on eliminating waste

Question 4

Waste

Answer 4

any activity that does not add value to the good or service in the eyes of the consumer (“muda”)

Question 5

Another word for Waste

Answer 5

Muda

Question 6

Source of waste: Overproduction

Answer 6

producing too much, stuck with inventory/throwaway

Question 7

Source of waste: Waiting

Answer 7

inefficient layout = idle time

Question 8

Source of waste: Unnecessary Transportation

Answer 8

within facility, across supply chain (any movement risks breakage)

Question 9

Source of waste: Inappropriate Process

Answer 9

not the correct functionality

Question 10

Source of waste: Unnecessary Inventory

Answer 10

Holding Costs

Question 11

Source of waste: Defects

Answer 11

errors

Question 12

Source of waste: Underutilization of employees

Answer 12

employees/machines not working to full potential/need

Question 13

Source of waste: Unnecessary/Excess motion

Answer 13

too much movement of a product, more likely to break

Question 14

Lean perspective on inventory

Answer 14

after a successful lean program has been put in place, wasted movement and space are eliminated and work centers are moved closer together; inventory levels are reduced dramatically and wo centers make only what is needed when it is needed

Question 15

Result of excess inventory

Answer 15

hides the problems that may occur but at a cost (masks issues)

Question 16

Lean Six Sigma

Answer 16

a methodology that combines organizational elements and tools of Six Sigma (process mapping, statistics, DMAIC cycle) with Lean’s focus on waste reduction

Question 17

Lean Supply Chain Management

Answer 17

an extension of the Lean philosophy that seeks to minimize the level of resource required to carry out ALL supply chain activities, not just production

Question 18

Kanban Systems

Answer 18

a production control approach that uses containers, cards, or visual cues to control the production and movement of goods through the supply chain

Question 19

Uses __ mechanisms to indicate when specific items should be produced or moved ; most do not require __

Answer 19

specific ; technology

Question 20

Kanban are not considered planning tools but

Answer 20

rather control mechanisms that are designed to pull parts or good through the supply chain based on downstream demand

Question 21

Two Card Kanban System

Answer 21

a special form of the Kanban system that uses one card to control production and another card to control movement of the materials (pull; demand-based)

Question 22

Move Card

Answer 22

a Kanban card that is used to indicate when a container of parts should be moved to the next process step

Question 23

Production Card

Answer 23

a Kanban card that is used to indicate when another container of parts should be produced

Question 24

Number of production Kanbans required (formula)

Answer 24

y= DT(1+x)/c

Question 25

what does each letter mean in the Kanban formula

Answer 25

y= number of kanbans d= demand per unit of time t= time it takes to produce and move a container of parts to the downstream demand point x= safety factor (expressed as a decimal) c= container size