Lecture 5: Aggregate planning, JIT, Lean, TPS

Question 1

What are swith over times?

Answer 1

This is the time it takes to change production from one product to another

Question 2

What are the steps in planning?

Answer 2

1. Set goals and objectives
2. Determining steps to achieve goals
3. Setting start and completion dates
4. Assign responsibility

Question 3

Name and describe the three planning horizons

Answer 3

1. Strategic: long-term plans of multiple years made by top executives
2. Tactical: Intermediate plans of 3 to 18 months. Made by operations manager
3. Operational: short-term plans from today to 3 months. Made by operations management or supervisors

Question 4

What is aggregate planning?

Answer 4

Aggregate planning is focused on providing quality and timing of production for the intermediate future. It comines production and involves capacity and demand variables

Question 5

Name the four aggregate planning goals?

Answer 5

1. Meet demand
2. Meet inventory policy
3. Use capacity efficiently
4. Minimize costs

Question 6

What are the aggregate planning strategies?

Answer 6

1. Capacity options - change capacity
2. Demand options - Change demand

Question 7

What is the difference between a level and chase strategy?

Answer 7

A level strategy means the production rate is constant

A chase strategy means the production rate equals demand

Question 8

What is Just-in-time?

Answer 8

Its a strategy where supplies are pulled through the system to arrive where they are needed when they are needed

It strives for continuous improvement

Question 9

How is aggregate planning used when providing services?

Answer 9

Its an attempt to allocate fixed capacity of a service to maximize profit/yield

Question 10

Name four side-features of just-in-time?

Answer 10

1. Attack waste
2. Exposes problems and bottlenecks caused by variability
3. Achieve streamlined production
4. Maintain respect for all workers

Question 11

What is lean production?

Answer 11

Lean production means customer is supplied with exactly what he wants, when he wants it, without waste, through continuous improvement

Question 12

Name the seven wastes of JIT?

Answer 12

1. Overproduction
2. Inefficient processing
3. Waiting
4. Inventory
5. Transportation
6. Unnecessary motion
7. Product defects

Question 13

Why does variability occur?

Answer 13

1. Products are not up to standards
2. Engineering drawings are inaccurate
3. Production before drawing is completed
4. Unknown customer demands

Question 14

What are push systems?

Answer 14

Systems where material is pushed into downstream workstations whether its needed or not

Question 15

How can you reduce setup/changeover times?

Answer 15

1. Modular product design
2. Group technology
3. Flexible production automation
4. Shigeo shingo

Question 15

What are pull systems?

Answer 15

Systems where material is pulled into a workstation just as it is needed.

Question 16

Name the 5 results of JIT?

Answer 16

1. Reduction in queue and delay
2. Quality improvement
3. Cost reduction
4. Variability reductions
5. Rework reduction

Question 17

What is shigeo shingo?

Answer 17

This is a concept of how companies can minimize setup times and contains:
1. Distinguish between external and internal setup times.
2. Make internal setup time external
3. Reduce internal setup time

Question 18

What is external setup time?

Answer 18

This is the required time to setup a batch that can be done while production is still running

Question 19

What are transformation systems?

Answer 19

These systems revolve around planning and involves the timing of operations using JIT principles.

Question 20

Should companies produce large or small lot sizes?

Answer 20

Companies should produce in small lot sizes to be able to better meet customer demand. BUT, this can only be done when setup times are small

Question 21

What is kanban?

Answer 21

This authorized production from downstream operations. Often used with fixed-sized containers

Question 22

What are five potential problems of implementing JIT?

Answer 22

1. applicable primarily to repetitive operations
2. Requires discipline
3. Based on trust and cooperation
4. PRoblem dealing with uncertainty
5. Requires change of philosophy.