Chapter 7 Just in Time and Lean Systems

Kanban card

A card that specifies the exact quantity of product that needs to be produced.

Uniform plant loading

A constant production plan for a facility with a given planning horizon.

Production card

A kanban card that authorizes production of material.

Withdrawal card

A kanban card that authorizes withdrawal of material.

Continuous improvement (kaizen)

A philosophy of never-ending improvement.

A broad view of JIT

A philosophy that encompasses the entire organization.

Quality circles

A team of volunteer production employees and their supervisors who meet regularly to solve quality problems.

Respect for people

An element of JIT that considers human resources as an essential part of the JIT philosophy.

Flexibility

An organizational strategy in which the company attempts to offer a greater variety of product choices to its customers.

Waste

Anything that does not add value.

Jidoka

Authority given to workers to stop the production line if a quality problem is detected.

Defining beliefs of JIT

Broad view of operations, simplicity, continuous improvement, visibility, and flexibility.

How can services improve quality through JIT?

Building quality into the process

External setup

Can be performed while the machine is still running.

Multifunction workers

Capable of performing more than one job.

Bottom-round management

Consensus management by committees or teams.

Setup cost

Cost incurred when setting up equipment for a production run.

Managers take on more of a supportive function in the JIT environment. Aside from being a coach and motivator, assisting with teamwork and problem solving, what is the MOST important thing managers can do for employees to help facilitate implementing JIT?

Create cultural change

Which of the following is a role of management in JIT? Serve as bosses. Develop an incentive system. Hold workers accountable for errors. Provide single-function training.

Develop an incentive system.

Poka-yoke

Foolproof devices or mechanisms that prevent defects from occurring.

Just-in-time (JIT) philosophy

Getting the right quantity of goods at the right place at the right time.

Which of the following is a benefit of JIT? Reduced flexibility Increased productivity Longer lead times Larger lot sizes

Increased productivity

Which is TRUE about JIT manufacturing? It relies on high technology to produce quickly at low cost. It relies on a coordination system called kanban that withdraws parts from a previous work center and moves them to the next. It is based on push production. It focuses on mass manufacturing processes.

It relies on a coordination system called kanban that withdraws parts from a previous work center and moves them to the next.

Pull system

JIT is based on a "pull" system rather than a "push" system.

Which of the following is TRUE about JIT manufacturing? JIT relies on production in anticipation of demand. JIT relies on a push system based on a forecast of demand. JIT relies on inventory to meet demand. JIT relies on a pull system. If products are not requested, they are not produced.

JIT relies on a pull system. If products are not requested, they are not produced.

Which is TRUE about JIT manufacturing? The ultimate goal of JIT is to produce in a lot size of 50 at a time. Setup cost is low in traditional manufacturing systems but high in JIT. Setup time is short in JIT systems but as a result cost is high. Low setup times in JIT mean that small lot sizes of products can be produced as needed and that production lead times will be shorter.

Low setup times in JIT mean that small lot sizes of products can be produced as needed and that production lead times will be shorter.

Which of the following is true about JIT implementation? JIT creates an "us-versus-them" attitude. Workers creates the right atmosphere. Managers develop reward systems for ideas and team cooperation. Management provides lip service to the concept.

Managers develop reward systems for ideas and team cooperation.

Types of waste

Material, energy, time, and space.

Total quality management (TQM)

Philosophy that seeks to improve quality by eliminating causes of product defects and by making quality the responsibility of everyone in the organization.

Cell manufacturing

Placement of dissimilar machines and equipment together to produce a family of products with similar processing requirements.

Visibility

Problems must be visible to be identified and solved.

Internal setup

Requires the machine to be stopped in order to be performed.

Which of the following is considered to be a key element of JIT supplier relationships? Short-term supplier relationships developed Suppliers viewed as the internal factory Suppliers located near the customer Use of multiple-source suppliers

Suppliers located near the customer

Single-source suppliers

Suppliers that supply an entire family of parts for one manufacturer.

Broad view of the organization

Tasks and procedures are important only if they meet the company's overall goals.

Small-lot production

The ability to produce small quantities of products.

Quality at the source

The belief that it is best to uncover the source of quality problems and eliminate it.

Just-in-time manufacturing

The element of JIT that focuses on the production system to achieve value-added manufacturing.

Simplicity

The simpler a solution, the better it is.

JIT system

The three elements are just-in-time manufacturing, total quality management, and respect for people.

What is one reason that companies fail to gain the benefits of JIT?

They do not implement the culture necessary.

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

a broad view of operations.

In JIT, the role of production worker is to

be actively engaged.

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

cross functional

Quality is defined by the

customer.

The central belief of the JIT philosophy is

elimination of waste.

JIT requires compact layouts and increased visibility so

everyone can see what everyone else is doing.

JIT believes in developing __________ relationships with suppliers.

long-term

The use of __________ in service operations helps improve quality and customer responsiveness.

multifunctional workers

The notion that the root cause of quality problems needs to be identified is

quality at the source.

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

respect for people.

According to JIT, workers should perform

routine preventive maintenance activities.

The challenge for service operations is _____ their production ________ demand.

synchronizing; with

In companies trying to increase speed, one strategy is to eliminate

unnecessary activities.