JIT & JIDOKA

Question 1

A problem gets automatically detected, stops the machine (or process) and alerts the operator to take action.

Answer 1

Autonomation

Question 2

making products or delivering services based on actual customer demand

Answer 2

Just-In-Time (JIT)

Question 3

Pillars of Lean

Answer 3

JIT and Jidoka

Question 4

Inventory is a form of waste (true or false)

Answer 4

True

Question 5

Task-switching is a form of waste (true or false)

Answer 5

True

Question 6

German word for beat or pulse

Answer 6

Tact Time

Question 7

Leveling out the demand over a period of time when you know there will be fluctuations in demand at work.

Answer 7

Heijunka = “leveling”

Question 8

Automation vs. Autonomation

Answer 8

Autonomation is automation with a human touch

Question 9

“Paper Lantern”
Refers to any visual display that shows status information

Answer 9

Andon

Question 10

a mechanism, usually a rope, that a worker may pull to signal the need for assistance, and which will stop the line if the problem is not fixed under Takt time.

Answer 10

Andon Cord

Question 11

a position on the assembly line where a zone process is completed. It is at these positions that the line will stop should an abnormality not be corrected on time - at the end of takt time.

Answer 11

Fixed-Position Stop

Question 12

-“mistake-proofing” or “error-proofing”
-Techniques using low-cost devices or innovations that make it impossible to make mistakes
-Helps people process work right the first time.

Answer 12

Poke-Yoke

Question 13

Which methodology asks the following questions?
*What’s needed?
*When is it needed?
*What’s the amount?
*How high in quality?

Answer 13

JIT

Question 14

Which methodology asks the following questions?
*Has the system been error proofed?
*Has a stop-gap been established?
*Has root cause been identified?

Answer 14

Jidoka

Question 15

The concept of building quality into a process yet not having to inspect it is part of which methodology

Answer 15

Jidoka

Question 16

Which of the following is not a step in Jidoka?

Answer 16

Don’t stop the production

Question 17

Autonomation is a lean methodology word for automation

Answer 17

False

Question 18

Can complex decisions be automated?

Answer 18

✓Yes, Nothing is too complex to be automated.
✓Decisions simply must be identified and broken down into MECE (mutually exclusive, comprehensively exhaustive) criteria in order to automate complex processes.

Question 19

Can a state of “true automation” ever be reached?

Answer 19

✓True automation can never be achieved as processes are constantly changing and there is always the possibility of errors/defects.
✓However, simple processes can be automated to the point where errors are so low that they are practically at a state of “true automation”.

Question 20

Business processes must be analyzed and built for

Answer 20

Automation

Question 21

_____ is the creation of processes that can operate with little or no human intervention.

Answer 21

Automation

Question 22

It is at the _____ of a process where automation can be applied.

Answer 22

Decision Points

Question 23

Which methodology do these statements describe?
*Don’t buy or deliver any unnecessary materials.
*Don’t produce products without an order.
*Sell products as soon as production is completed.

Answer 23

JIT

Question 24

Which methodology do these statements describe?
*Don’t manufacture defective parts.
*Don’t pass the defective parts onto the following process.

Answer 24

Jidoka

Question 25

What are the 6 Basic Steps of Jidoka?

Answer 25

1 The machine detects an abnormal condition. 2 The machine stops itself. 3 Implement a stopgap. 4 Resume production. 5 Identify the root cause. 6 Fix the problem.

Question 26

What are the Tools of Jidoka

Answer 26

*Andon *Andon Cord *Fixed-position stop *Poka-Yoke *Jidoka Board

Question 27

A board with issues and ideas that can be voted on. An improvement owner will be assigned to the issues and ideas with the most votes.

Answer 27

Jidoka Board

Question 28

What are some of the benefits of Jidoka?

Answer 28

*Prevents defective items from being delivered to the next process *Prevents equipment breakdown *Produces higher quality of products *Minimize poor quality *Improves productivity (saves cost and time) *Ensures & maintains safety *Empowers people

Question 29

Stop the Line is a principle of which of these methodologies? a) Flow b) Kanban c) Jidoka d) Just-In-Time (JIT)

Answer 29

c) Jidoka

Question 30

The concept of building quality into a process yet not having to inspect it is part of which methodology? a) Jidoka b) Just-In-Time c) Andon d) Flow

Answer 30

a) Jidoka

Question 31

Which one of the following is not a step in Jidoka? a) Detecting occurrence of any deviation b) Corrections or repair work c) Investigating the Root Cause of the Defect d) Don’t stop the production

Answer 31

d) Don’t stop the production

Question 32

Autonomation is a lean methodology word for automation. a) True b) False

Answer 32

b) False