Tutorial A3 q1-10

Question 1

What is the main concept behind the Toyota Production System?

Answer 1

Eliminating unnecessary resources (reducing ‘waste’) hence increasing production efficiency and effectiveness
Produce the required product:
-At the right time
-In the right quantity
-To the right quality 
i.e. ‘Just-in-time’.

Question 2

Is ‘Just-in-time’ production a pull or push system?

Answer 2

Pull system

Question 3

Why is JIT production a pull system?

Answer 3

Each stage initiates production by requesting an order from the previous stage in the production process

Question 4

What are the benefits of a ‘Just-in-time’ process? (5)

Answer 4

• Bottlenecks are eliminated
• Batch sizes are reduced
• Waiting time of parts is reduced
• WIP is reduced (hence holding/storage cost is also reduced)
• Set up time is reduced

Question 5

What are the 7 ‘wastes’?

Answer 5

1. Zero defects
2. Zero inventories
3. Zero setup times
4. Zero handling
5. Zero breakdowns
6. Zero lead times
7. Batch size of one

Question 6

How is JIT production controlled?

Answer 6

With a Kanban system where a Kanban card (or electronic equivalent) authorises the manufacture of components once the subsequent process is complete

Question 7

How does Kanban help identify ‘wastes’?

Answer 7

A build-up of Kanban cards indicates more WIP and the location of a bottleneck

Question 8

What is ‘quality’ from the point of view of a customer?

General

Answer 8

Does the product meet my needs and expectations?

Question 9

What is ‘quality’ from the point of view of a customer?

Quantitative (3)

Answer 9

-Speed
-Lightness
-Value
etc

Question 10

What is ‘quality’ from the point of view of a customer?

Qualitative (3)

Answer 10

-Attractive
-‘Cool’
-Brand loyalty
etc

Question 11

What is ‘quality’ from the point of view of a
manufacturer?
General

Answer 11

Have we made the product to the exact specification that we intended?

Question 12

What is ‘quality’ from the point of view of a
manufacturer? (2)
Quantitative

Answer 12

-Geometrical tolerances
-Surface finish
etc

Question 13

What is ‘quality’ from the point of view of a
manufacturer? (2)
Qualitative

Answer 13

-Visual inspection
-Perceived build quality
etc

Question 14

What is Quality Assurance (QA)?

Answer 14

An iterative system for preventing defects as far as possible.
Products should be ‘fit for purpose’ and mistakes should be minimised so products are ‘right first time’.

Question 15

What is Quality Control (QC)?

Answer 15

System for detecting defects in a product/process. QC is a key part of the QA process where the size and frequency of defects are detected.