WGU 215 Ch 7

JIT manufacturing

-JIT manufacturing enables the right quantities of parts to arrive when they are needed precisely where they are needed. -Is a philosophy based on the elimination of waste. -JIT manufacturing views inventory as a waste that needs to be eliminated.

3 Elements of JIT

1. JIT Manufacturing 2. TQM 3. Respect for people

An employee who will not help a customer because "it is not my job" violates the JIT belief of Simplicity A broad view of operations Continuous improvement Visibility Pull production

A broad view of operations

Kanban Card

A card that specifies the exact quantity of product that needs to be produced. Kanban cards create the "pull" in the JIT pull systems. In effect, the kanban is a production authorization record.

Continuous Improvement (Kaizen)

A philosophy of never-ending improvement.

TQM

A philosophy that involves everyone in an organization in a continual effort to improve quality and achieve customer satisfaction.

Work cell

An arrangement of machines and personnel that focuses on making a single product or family of related products. The equipment in a work cell is usually arranged in a U shape, with the worker placed in the center of the U.

In JIT the workforce is viewed as another resource to be managed another contractual obligation a long-term asset a short term asset an asset that must be closely managed

a long-term asset

Waste in JIT

Anything that does not add value

If the goal is to reduce the amount of inventory in the system, the number of Kanban cards should Be decreased Be increased Remain the same Be calculated by formula Remain the same, but container size should be increased

Be decreased

External setups

Can be done while the machine is running

JIT and flexibility

Can mean being flexible on the volume of production and being able to produce a variety of products. Part of the JIT philosophy is to design operations that are highly efficient but flexible in order to accommodate changing customer demands.

Just-in-time relies on ___________ worker skills, meaning the ability of workers to perform many different tasks on many different machines. Natural Verbal Intuitive Manual Cross functional

Cross functional

Quality is defined by the Quality Control department Marketing department Board of directors Customer Auditors

Customer

JIT (Pull System)

Each station requests the precise amount of products that is needed from the previous workstation. If products are not requested, they are not produced. In this manner, no excess inventory is generated. Pull systems work backwards. The last workstation in the production line (or the customer) requests the precise amounts of materials required.

Being able to keep costs low while changing the volume of production is an example of Simplicity Flexibility Visibility Continuous improvement Total quality management

Flexibility

Quality at the source

Identifies the quality problem AND identifies the root of the problem. Example, burnt cookies, baking time is too long.

JIT (just in time)

In the simplest form means getting the right quantity of goods at the right place and at the right time. Allows plants and raw materials to be delivered to production plants just before they are needed. The central belief of the JIT philosophy is the elimination of waste. JIT is an all-encompassing philosophy that affects every level and function of the organization. Developed by Toyota in 1970s

According to JIT, __________ is carried to cover up a wide variety of problems, such as poor quality, demand uncertainty, and slow delivery. Inventory Excess capacity A group of back-up workers Spare equipment Insurance

Inventory

JIT and respect for people

JIT considers people to be a company's most precious resource. The JIT philosophy believes in treating all employees with respect, providing job security, and offering significant rewards for well-performed tasks. Respect for people extends to suppliers. JIT believes in developing long-term relationships with suppliers in a partnership format.

JIT believes in developing __________ relationships with suppliers. Long-term Adversarial Arms-length Temporary Distant

Long-term

Types of waste in JIT

Materials like excess inventory, equipment that is only used as a backup because regular equipment breaks down, time, energy, space, transportation, poor quality, or human activity that does not contribute to the value of the product or service.

JIT and Visibility

Part of the JIT philosophy is to make all waste visible.

cell manufacturing

Placement of dissimilar machines and equipment together to produce a family of products with similar processing requirements. These machines create a small assembly line, and their grouping is usually called a cell.

According to JIT, by eliminating inventory we can clearly identify __________ and work on eliminating them. Obsolete products Malfunctioning machines Grievances Product imperfections Problems

Problems

The system of Kanbans used to coordinate delivery of goods by suppliers can include all of the following except Filled containers delivered by the supplier Purchase approvals by the production manager Mail boxes for each supplier Empty containers with a Kanban Bar-coded Kanbans

Purchase approvals by the production manager

Beliefs that help define the JIT philosophy include all of the following except Simplicity Visibility Flexibility Push production Continuous improvement

Push production

Push-type systems

Push systems anticipate future demand and produce in advance in order to have products in place when demand occurs. Products are pushed through the system and are stored in anticipation of demand, which often results in excess inventory. Traditional manufacturing systems use "push" production, whereas JIT uses "pull" production.

Internal setups

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

Three basic elements work together to complete a JIT system: just-in-time manufacturing, total quality management, and Quality circles Pull production Minimizing inventory Respect for people Full utilization of capacity

Respect for people

JIT manufacturing cannot succeed if __________costs are too high. Variable Fixed Set-up Depreciation Marginal

Set-up

What is the term used for the adjustment of a machine after making one product type so that production can begin for another product type? Level assembly schedule Group technology Setup Cycle time Automation

Setup

Broad view of the organization

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

Small Lot Production

The ability to produce small quantities of products

In JIT a Kanban card is used to signal The need for more parts A supplier needs assistance A worker is overloaded A machine is ready for preventive maintenance Management is inspecting operations

The need for more parts

JIT and simplicity

The simpler the better.

Multifunction workers

They are trained to operate, maintain, and set up different machines. A multifunction worker can operate more than one machine at a time.

Managers become more of a supportive function in the JIT environment. Aside from being a coach, motivator, assisting with teamwork and problem solving, what is the most important thing managers can give to employees to help facilitate implementing JIT? money food free access to the gym time high appraisal

Time

Uniform Plant Loading or leveling

To meet demand and keep inventories low, a "level" schedule is developed so that the same mix of products is made every day in small quantities.

Flexible Resources

Uses general-purpose equipment capable of performing a number of different functions to meet customer demands and produce small lots. Think of a printer/copier/fax machine all in one.

Self-managed teams

Workgroups that supervise themselves and all aspects of their business. Often used in JIT companies.

JIT applies to only the manufacturing organization only the service organization both the manufacturing and service organizations only the production portion of manufacturing and service organizations all of the organization except the marketing division

both the manufacturing and service organizations

One of the greatest benefits of JIT would be increasing waste and improving responsiveness longer lead times and increased productivity decreased machine utilization and improved quality competing based on schedules eliminating waste, improving responsiveness and competing based on time

eliminating waste, improving responsiveness and competing based on time

The central belief of the JIT philosophy is quality must be emphasized use of Kanban elimination of waste minimize inventory save money

elimination of waste

JIT requires compact layouts and increased visibility so light can be minimized throughout the plant the kanban color codes can be determined everyone can see what everyone else is doing everyone will know when to go on break one person can handle the full process all the time

everyone can see what everyone else is doing

One outcome of a U-shaped cell manufacturing layouts is increased labor per hour cost for higher skilled workers decreased labor per hour cost for lower skilled workers improved external supplier response times increased worker satisfaction decreased worker satisfaction

increased worker satisfaction

An improvement tool that utilizes cross-functional teams to plan and deliver improvements to specific processes during two- or three-day marathon sessions is called a ___________________. kanban blitz cross-functional blitz short-term blitz JIT blitz kaizen blitz

kaizen blitz

The broad view of JIT is now often termed __________________________. vendor-managed inventory business process reengineering lean production cycle time management e-distribution

lean production

In making specific changes to JIT manufacturing, which of the following steps should come first? reduce lot sizes and lead times switch to pull production reorganize workplace reduce setup times implement layout changes

reorganize workplace

According to JIT, workers should perform system specification development as directed by the supervisor routine preventive maintenance activities poka-yoke designs quality program development

routine preventive maintenance activities

Single setup means

setup times are in single digits of minutes

Single setup means performing only one setup at a time restricting setup to one machine at a time extend external setup to include one supplier setup times are in single digits of minutes external and internal setup times are the same

setup times are in single digits of minutes

Which of the following is not considered to be a key element of JIT supplier relationships?* suppliers viewed as internal factory use of single-source suppliers long-term supplier relationships developed suppliers locate near customer cost and information sharing

suppliers viewed as internal factory

JIT was based on the need for a new management fad new consulting revenue stream a need for shorter supply lines survival a new vision

survival

Marketing plays a large role in JIT because it sets the production rates it provides all forecasts it develops the conceptual designs they pass on the customer-driven quality requirements they need JIT to increase their performance bonuses

they pass on the customer-driven quality requirements

JIT flexibility refers to ability to modify sales figures correct the bull whip effect increase or decrease supplier deliveries on short notice workers being able to perform many different tasks managers being able to shift positions easy

workers being able to perform many different tasks