Brainscape's Knowledge GenomeTM

Browse over 1 million classes created by top students, professors, publishers, and experts.


See full index

MOS 3330 > Final - JIT Systems > Flashcards

Final - JIT Systems Flashcards

1
Q

JIT

A

Just-in-time manufacturing: to produce only what is needed, when it is needed

JIT inventory, JIT purchasing, lean manufacturing

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
2
Q

JIT philosophy

A

Eliminate all waste i the organization

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
3
Q

JIT system

A

a management system that aims to improve the manufacturing or service process by eliminating waste

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
4
Q

Origins of JIT systems

A

In 1950s, Toyota realized there were all kinds of waste in the production process because of how little capital and space Japan had, forcing them to minimize inventory

Felt that inventory hides problems. For Toyota, improving performance meant reducing inventory.

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
5
Q

waste

A

anything other than the minimum amount of resources that is essential to add value to the product

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
6
Q

Examples of process waste

A

scrap, non-value-added cost, wrong tools/equipment

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
7
Q

Examples of over-production waste

A

extra inventory, inappropriate use of resources

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
8
Q

Examples of inventory waste

A

storage, capital costs

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
9
Q

Examples of product defect waste

A

interrupted flow, lost capacity, wait for replacements

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
10
Q

Examples of waiting time waste

A

unplanned, planned queue, waiting for other parts in batch

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
11
Q

Examples of methods waste

A

searching for tools, poor layout, walking

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
12
Q

Examples of movement waste

A

material handling, receiving, storing, retrieiving

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
13
Q

How can managers improve the pull system?

A

reduce the variability associated with supply and demand

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
14
Q

pull system

A

coordination between process -> improving means eliminating the need for large inventory (which is a major issue in automobile manufacturing)

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
15
Q

work cells

A

Eliminating worker inefficiency = increasing worker productivity

highly utilized multifunctional workers operating a number of different machines

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
16
Q

Cellular facility layout

A

work is moved within a cell (mostly U shaped) according to a prescribed path (as opposed to assembly lines typical in traditional automobile production)

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
17
Q

Flexible machines

A

automated, general purpose machines with quick setup times

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
18
Q

cell

A

grouping of products based on similar requirements

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
19
Q

Should a company implement work cells if employees need to constantly tend to the product?

A

No, because work cells only work if the workers don’t need to be at the same step in the product all the time (they rotate between steps)

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
20
Q

push system

A

each workstation produces according to a schedule and ‘pushes’ its completed work to the next workstation (aka the traditional approach to production by building inventory)

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
21
Q

pull system

A

each workstation requests, or ‘pulls’ items from the previous workstation only when needed

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
22
Q

What are the benefits of a pull system?

A

Overall: Improves coordination between processes by force

Prevents overproduction and underproduction

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
23
Q

Kanban system

A

Visible production control system which authorizes the production or movement of the next batch of material only when needed

Works the same way as a fixed-quantity inventory system: Order quantity (Q) is equal to reorder point (R)

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
24
Q

What are kanbans NOT?

A

Not schedules!

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
25
Q

MRP vs. Kanban

A

schedule vs. cue
complex vs. repetitive
higher-level vs. shop-level control

How well did you know this?
1
Not at all
2
3
4
5
Perfectly
26
Q

production lot

A

aka batch; the typical amount of items produced in one session

27
Q

true or false: compared to a large lot size, a small lot size is harder to achieve between-process coordination that’s required for the pull system

A

false; easier because there’s less room for error/steps involved (my assumption)

28
Q

What are the benefits of small lot sizes?

A

Better coordination
Better material handling
Reduce average inventory levels
Reduce inventory space
Avoid buildup of defective items
Flexibility in reacting to problems

29
Q

What does each ‘kanban’ container represent?

A

Production or order lot size

30
Q

What are the 4 different types of supply variability?

A

lot size, machine breakdowns, quality, suppliers

31
Q

preventative maintenance

A

periodic inspection and maintenance designed to avoid breakdowns (as opposed to breakdown maintenance)

necessary due to small inventory and high automation

32
Q

work environment: five S’s

A

there are 5 S’s that make up a work environment (don’t need to know what they mean, just that they exist). Seiri, seiton, seiso, seiketsu, shitsuke.

Stuff like cleanup, workplace organization, discipline, etc. Basically JIT systems prioritize preventative maintenance and workplace organization to be effective.

33
Q

Why are consistently high quality products necessary in JIT systems?

A

Due to the small inventory

34
Q

Why do facilities and equipment need to be kept in good working order (maintenance) in JIT systems?

A

Because machine downtimes are waste. Fixing is also waste.

35
Q

Empowerment

A

authority given to workers to stop the production line if a problem occurs

Andon lights typically used to signal issues.

36
Q

Why do JIT systems focus on fixing quality problems at the source?

A

Because it’s not easy to coordinate between processes if product quality is poor.

Ex. Workers might not have enough good quality items to continue work, or time might be spent on fixing defective items

37
Q

poka-yoke

A

devices that are designed to prevent mistakes/defects from happening

38
Q

What do standard parts and modular design of products help with?

A

reducing variability

39
Q

Why are reliable suppliers important for JIT systems?

A

So that deliveries are on-time and frequent. Must build long-term, close relationship with. few suppliers.

40
Q

What sourcing method of suppliers is best in JIT?

A

Single-sourcing: entire family of parts provided by one supplier to minimize time etc. between deliveries (prevent bottlenecks)

prefer physical proximity but not necessary

41
Q

JIT II

A

Supplier working in the manufactuer’s plant.

42
Q

What are the pros and cons of a supplier establishing a relationship with a company employing a JIT system?

A

Pros:
- Guaranteed, steady demand
- Advanced notice of volume changes
- Minimal design changes
Cons:
- Lots of requirements
- Competitive vs. cooperative dilemma
- All eggs are in one basket

43
Q

JIT systems are most successful in which industries in relation to demand?

A

Industries that have a relatively consistent demand due to JIT being effective with minimal demand variability

44
Q

Kanban systems can absorb +/- what % of demand variability through manipulating the number of kanbans?

A

10%

45
Q

True or false: the fewer the kanbans, the less production there is

A

true

46
Q

How can worker cells deal with changes in product mix and volume?

A

Volume adjustment by a number of workers
Volume adjustment by integrating or separating cells

However, can only do so to a certain extent

47
Q

Uniform loading

A

Arrange daily production in the same ratio as monthly demand

Always have some quantities of each product and steady demand on components

48
Q

If a company implements a JIT system, what changes would be expected? (7)

A

Reduced Inventory > safety stock
Cells > assembly lines
Pull > push manufacturing
Zero defects > defect toleration
Quick setup times > toleration of set up times
Emphasize team-oriented employee involvement > IC contribution following manager instructions
Suppliers as partners > independent entities

49
Q

Why do JIT systems lead to shorter cycle times?

A

Because batch sizes are smaller

50
Q

What are some benefits of JIT systems?

A

REDUCE: inventory, space
IMPROVE: quality, process
PEOPLE: Better use of HR, supplier relations, employee engagement, productivity
SHORTEN: cycle time, lead time
PROCESS: increased machine utilization, greater flexibility, more product variety

51
Q

Limitations of JIT (aka issues)

A
  1. All key elements must be present and integrated for system to work well i.e. work cells, suppler variability, pull system, lot size (smaller), machine breakdowns, fewer suppliers, increase quality
  2. Must balance technical and behavioural aspects
  3. Each org must mould a JIT system to suit its own environment
  4. Requires fundamental change in the org
52
Q

JIT systems are not suited for companies that have..

A

Very high or low volume, unique products
High fluctuating demands or true make-to-order products

53
Q

What are the pros of job specialization for management?

A

Readily available labour
Minimal training
reasonable wage
high productivity

54
Q

What are the cons of job specialization for management?

A

High absenteeism
High turnover rates
high scrap rates
grievances filed (i.e. unsatisfied workers)

55
Q

What are the pros of job specialization for workers?

A

Minimal credentials
minimal responsibilities
minimal mental effort
reasonable wage

56
Q

What are the cons of job specialization for workers

A

Boredom
little growth opportunity
little control or initiative
little intrinsic satisfaction

just a cog in the wheel :(

57
Q

what are three types of alternative job designs?

A

job rotation, job enlargement, job enrichment

58
Q

job rotation

A

shifts workers to different jobs to increase understanding of the total process

59
Q

job enlargement

A

expansion of the job through increasing the scope of the work assigned (more horizontal)

60
Q

job enrichment

A

expansion of the job through increasing the worker responsibility (more vertical)

61
Q

method analysis

A

a type of work measurement that studies how a job is done; typically a document outlines how job is done and what is expected to be evaluated

62
Q

time study methods

A

sets a standard time based on timed observations of one worker over several cycles to measure work

63
Q

what do time study methods help with?

A

helps to reduce variability time in the production cycle and determine how long it takes to do each task

MOS 3330 (6 decks)

Brainscape helps you reach your goals faster, through stronger study habits.
© 2024 Bold Learning Solutions. Terms and Conditions