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 (D)</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 (A)</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 (B)</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 (B)</p> Signup and view all the answers

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

<p>Setup time reduction (D)</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 (B)</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 (C)</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 (C)</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 (B)</p> Signup and view all the answers

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

<p>Time study (C)</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 (A)</p> Signup and view all the answers

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

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

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

<p>Cleaning and inspecting the workstation area (D)</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 (C)</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 (D)</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 (C)</p> Signup and view all the answers

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

<p>Stable production conditions (C)</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 (D)</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 (B)</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 (D)</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 (A)</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 (A)</p> Signup and view all the answers

Why is setup time reduction important in JIT production?

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

Flashcards

Traditional Production

A manufacturing approach where products are made in large batches and stored in anticipation of demand.

JIT Production

A manufacturing system focused on producing goods only when needed, minimizing waste and inventory.

Just-in-case Inventory

Holding extra stock to avoid potential shortages, even if it means higher storage costs.

Minimum Inventory

Aiming to hold the least amount of inventory possible, reducing storage costs and waste.

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Acceptable Quality Level

A standard for acceptable defects in a product, often leading to rework or scrap.

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Taiichi Ohno

A VP at Toyota who led the development of the Lean and Just-in-Time (JIT) production system, focusing on eliminating waste in production.

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Seven Wastes (Muda)

Taiichi Ohno identified seven types of waste in production, including defective parts, excess production, unnecessary movement, and waiting.

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Just-in-Time (JIT) Production

A manufacturing approach where components are produced and delivered to the next stage of production only when needed, minimizing inventory and waste.

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Pull System

A production control method in JIT where downstream operations pull materials from upstream operations as needed.

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Setup Time Reduction

A key principle in JIT where the time required to set up equipment for production is minimized, allowing for smaller batch sizes.

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Stable & Reliable Production

A prerequisite for JIT, ensuring consistent on-time delivery, defect-free parts, and reliable equipment.

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Standardize Work Procedures

A key aspect of the Toyota system where tasks are standardized to ensure every product is made the same way, with consistent quality.

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Process Diagram (Flowchart)

A chart used to visualize the steps involved in a process, helping to identify opportunities for improvement.

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5S System

A method to organize and maintain a clean and efficient workspace by following five steps: Sort, Set in order, Shine, Standardize, and Self discipline.

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Sort (5S)

The first step in the 5S system where you identify and remove unnecessary items from the workspace to reduce clutter and improve efficiency.

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Set in order (5S)

The second step in the 5S system where you organize remaining items in a way that makes them easy to find and use.

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Shine (5S)

The third step in the 5S system where you clean and inspect the workspace to ensure everything is in its place and working properly.

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Standardize (5S)

The fourth step in the 5S system where you establish standard procedures and locations for items to ensure consistency in work processes.

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What is the Toyota Production System?

A manufacturing system aiming to eliminate waste (Muda) in all its forms, focused on delivering exactly what's needed, just when it's needed.

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What is the goal of Just-In-Time (JIT)?

To produce and deliver the exact quantity of each component to the next step in the manufacturing process, only when it's needed.

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What is a 'pull system' in JIT?

Downstream operations request materials from upstream operations only when needed, minimizing inventory storage.

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Why is setup time reduction essential for JIT?

Decreasing the time needed to switch between production runs allows for smaller batch sizes, reducing waste and inventory.

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What is a 'stable and reliable' production operation?

A production environment with on-time delivery of materials, defect-free parts, reliable equipment, and a skilled workforce.

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What is the goal of 'standardize work procedures'?

To establish a consistent process for making a product, ensuring every item is made the same way with high quality.

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What is a flowchart?

A visual representation of the steps involved in a process, used to analyze and improve efficiency.

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What is 'cycle time'?

The total time it takes to complete one cycle of producing a product.

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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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