Exam 13: Jitlean Production

Two modules are used to feed the final assembly station on an assembly line. The final assembly station must produce 250 units in an eight-hour day. Each finished unit needs two module A's and 3 module B's. The factory uses a standard sized container that can hold 25 module A's or 35 module B's. It takes 2 hours to fill and move a container of module A's, but only 90 minutes to fill and move a container of module B's. If both module assembly processes have safety factors of 15%, how many containers should be used for each? How many hours of demand will this satisfy?

The number of kanbans in a production system is inversely related to the ________.

The cards employed in a two-card kanban system are the production card and the move card.

A pull system is a production system in which actual downstream demand sets off a chain of events that pull material through various steps in the various process steps.

________ could result in workers from one company working to eliminate waste for a company from which they purchase components.

What is the Lean perspective on inventory?

The underlying emphasis of Lean is the elimination of ________.

Use this material requirements planning record to explain how kanbans and MRP can be used together. This plant operates on a 40-hour week, and uses a 10% safety factor on a container size of 20 units with a half-day turnaround time on a container. What features of each system should be used and for what purposes? Week 1 2 3 Gross Requirement 900 1000 1100 Scheduled Receipts 0 0 0 Projected Ending Inventory 0 0 0 Net Requirements 900 1000 1100 Planned Receipts 900 1000 1100 Planned Orders 900 1000 1100

Some companies have found it beneficial to combine the planning capabilities of kanban with the control capabilities of MRP.

The forecast for next month is 200 units so the manufacturer gathers materials for this anticipated level of production activity. This is an example of a pull system.

Liversuch Industries uses a kanban system to manage production of the J-15 subassembly. They have an hourly demand for 250 units and use containers that can hold 50 units each. It takes 90 minutes to fill and move a container of parts to the right place on the J-15 line that is currently rated at a 20% safety factor. How many production cards are needed?

The just-in-time philosophy applies only to the production floor of a manufacturing company.

Two announcers are used to read names at the semiannual commencement exercises held at a regional university in America's heartland. All students have their names read then walk briskly to the president who shakes their hand and offers them an empty diploma cover until such time that all financial obligations to the university have been met. The president greets about 900 students in an eight-hour day. The diploma covers come in boxes of 12 and it takes one hour to carry one from the receiving dock to the field house where the ceremony is held. The president likes to keep things moving, so he has requested a 50% safety factor. How many containers are needed?

In the water and rocks analogy for Lean:

Consider the adjacent work stations in this two card kanban system. Work Center 3 has just pulled the Incoming Parts C box to their work station. Which of these statements is best?

An increase in the safety factor results in an increase in the amount of inventory in a kanban system.

Once a system has been "leaned out" with all excess inventory removed, if a piece of production equipment breaks, all activity on the production line ________.

What are the consequences of unstable demand and interrupted flows on a supply chain managed with a Lean philosophy?

Livermore Industries uses a kanban system to manage production of the KR-9 subassembly. In a ten-hour day, they use 1500 units and use containers that can hold 50 units each. It takes 45 minutes to fill and move a container of parts to the right place on the KR-9 line that is currently rated at a 15% safety factor. How many production cards are needed?

Livernonions Industries uses a kanban system to manage production of the BR-549 subassembly. In an eight-hour day, they use 900 units and use containers that can hold 30 units each. It takes 120 minutes to fill and move a container of parts to the right place on the BR-549 line that is currently rated at a 15% safety factor. How many production hours of inventory are needed?