Lean & Just-in-Time (JIT) Production
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Questions and Answers

What is the primary focus of Just-in-Time (JIT) production compared to traditional production?

  • Ensuring workers are told what to do
  • Maintaining just-in-case inventory
  • Utilizing inflexible production processes
  • Striving for continuous improvement (correct)

    • Which principle is NOT part of the 5S system?

  • Standardize
  • Self-discipline
  • Set in order
  • Just-in-case inventory (correct)

    • In a Just-in-Time production environment, what aspect of inventory management is prioritized?

  • Increasing acceptable quality levels
  • Utilizing inflexible delivery schedules
  • Having a high level of just-in-case inventory
  • Maintaining minimum inventory levels (correct)

    • Which of the following is a key characteristic of worker involvement in Just-in-Time production?

    <p>Worker empowerment and teamwork</p> Signup and view all the answers

    What is the primary goal of standardizing processes in the 5S system?

    <p>To eliminate variations from processes</p> Signup and view all the answers

    What is one of the main goals of Taiichi Ohno in developing the Toyota Production System?

    <p>Eliminate waste in production operations</p> Signup and view all the answers

    Which of the following is NOT one of Taiichi Ohno's seven forms of waste?

    <p>Utilization of overqualified workers</p> Signup and view all the answers

    What is a prerequisite for Just-in-Time (JIT) production?

    <p>Setup time reduction</p> Signup and view all the answers

    What policy can a company implement to improve its vendor relations under JIT?

    <p>Establish quality and delivery standards</p> Signup and view all the answers

    Which of the following is a key component of standardizing work procedures in the Toyota system?

    <p>Standardizing cycle times</p> Signup and view all the answers

    How should components be delivered in a Just-in-Time production system?

    <p>Just at the moment when needed</p> Signup and view all the answers

    What effect does reducing the total number of suppliers have in JIT?

    <p>Enhances the supplier’s ability to manage orders</p> Signup and view all the answers

    What method is used to determine cycle time in the Toyota system?

    <p>Time study</p> Signup and view all the answers

    What is the main focus of the 5S system in production management?

    <p>Creating an organized and efficient workplace</p> Signup and view all the answers

    Which principle differentiates Just-in-Time production from traditional production?

    <p>Empowering workers through team involvement</p> Signup and view all the answers

    What does the 'Shine' principle in the 5S system involve?

    <p>Cleaning and inspecting the workstation area</p> Signup and view all the answers

    In a Just-in-Time production environment, how is inventory managed?

    <p>Inventory is kept to a minimum near the production area</p> Signup and view all the answers

    What is the purpose of the 'Set in order' step within the 5S system?

    <p>To organize tools for easy access based on their usage frequency</p> Signup and view all the answers

    Which of the following defines one of Taiichi Ohno's seven forms of waste?

    <p>Having workers waiting for materials</p> Signup and view all the answers

    What is a fundamental requirement for a Just-in-Time (JIT) production system?

    <p>Stable production conditions</p> Signup and view all the answers

    In standardizing work procedures, what does the time study help to establish?

    <p>Length of time required to complete each task</p> Signup and view all the answers

    What is an important aspect of the pull system in a JIT production environment?

    <p>Order fulfillment based on actual demand</p> Signup and view all the answers

    Which aspect of supplier relations is promoted under JIT policies?

    <p>Building long-term agreements to stabilize supply</p> Signup and view all the answers

    Which of the following describes the primary goal of standardizing the cycle time in production?

    <p>To maintain a consistent production output rate</p> Signup and view all the answers

    What is the recommended approach regarding supplier diversity in JIT practices?

    <p>Reducing the total number of suppliers for better management</p> Signup and view all the answers

    Why is setup time reduction important in JIT production?

    <p>It contributes to faster delivery times.</p> Signup and view all the answers

    Study Notes

    Lean & Just-in-Time (JIT) Production

    • Developed by Taiichi Ohno, a VP, to eliminate waste in all forms in production operations.
    • Seven forms of waste (Muda):
      • Production of defective parts
      • Production of more parts than needed
      • Excessive inventories
      • Unnecessary movement of people
      • Unnecessary handling of materials
      • Having parts or workers waiting
      • Unnecessary processing steps
    • JIT Production: Delivering exactly the required components to the next stage of production just when needed.

    Prerequisites for JIT

    • Pull system of production control.
    • Reduced setup times for smaller batch sizes. Design the setup tooling and plan the changeover procedure to permit as much of the setup as possible to consist of external elements.
    • Stable and reliable production operations:
      • On-time delivery of components
      • Defect-free components and materials
      • Reliable production equipment
      • Cooperative workforce (committed and cross-trained)
      • Dependable supplier base

    Policies for Dealing with Vendors

    • Reduce the total number of suppliers.
    • Establish long-term agreements and partnerships with suppliers.
    • Set quality and delivery standards and select suppliers based on their capacity to meet these standards.
    • Employ company personnel at supplier facilities.
    • Select suppliers geographically close to the company to minimize transportation delays.

    Standardize Work Procedures

    • Standardize task sequences for product manufacturing (methods study) using flowcharts (process diagrams).
    • Standardize the cycle time for producing the product.
    • Time studies used to determine the task time and calculate the cycle time for the needed product.

    Traditional vs. JIT Production

    • Traditional Production: Just-in-case deliveries, just-in-case inventory, acceptable quality level, workers told what to do, inflexible production system, if it ain't broke, don't fix it.
    • JIT/Lean Production: Just-in-time deliveries, minimum inventory, strive for perfect first-time quality, worker teams/empowerment, flexible production systems, continuous improvement.

    The 5S System

    • A method for creating a neat, orderly, and efficient workplace.
    • Sort: Removing unnecessary items, eliminate clutter.
    • Set in Order: Organizing tools and materials according to frequency of use, provide easy access to items most often used.
    • Shine: Cleaning the workstation area, inspecting to ensure everything is in the proper place.
    • Standardize: Standardizing work procedures, location for tools. Goal is to remove variations from processes.
    • Self-Discipline: Each person at their station is responsible for taking care of their equipment, cleaning, performing minor maintenance tasks.

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    Description

    Explore the principles of Lean and Just-in-Time (JIT) production as developed by Taiichi Ohno. This quiz covers the elimination of waste through various strategies and policies for supplier management, emphasizing a pull system and standardized work procedures. Test your knowledge on effective production practices!

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