C215 - Chapter 7

Question 1

What is the JIT philosophy ?

Answer 1

• getting the right quantity of goods at the right place and the right time
• geared to eliminate waste — anything that does not add value.

Question 2

What are the 3 core elements of JIT?

Answer 2

1. JIT manufacturing: value-added manufacturing . producing goods only when they are needed, in the exact amount needed, and at the right time.
2. TQM : quality at its source. Only zero defects acceptable
3. Respect for people : human resources are essential

Question 3

6 Defining beliefs of JIT

Answer 3

1. Broad view of operations : everyone works towards the same goal
   - tasks and procedures are important only if they meet company’s overall goal
2. Simplicity — simple processes make problems easier to see and fix
3. Continuous improvement — never done improving, JIT never done being fully implemented
   - “kaizen blitz” : cross-functional teams to plan/deliver improvements in 2/3 day marathon sessions
4. Visibility — all waste must be visible to be identified and eliminated.
5. Flexibility — greater variety of product choices, make changes in volume of product produced
   - keep costs of facilities/equipment/operations at low level

6- waste elimination

Question 4

The 5 Key Elements of JIT Manufacturing

Answer 4

1- Kanbans and pull systems

2- small lot sizes and quick setups

3- uniform plant loading

4- flexible resources

5- efficient facility layouts

Question 5

JIT Manufacturing : Kanbans and pull systems

Answer 5

• Kanban = a visual signal (like a card or bin) that specifies exact quantity of product needed

•	Pull system = production happens only when the next step asks for it, not before.

👉 This prevents overproduction and excess inventory

• starts with last workstation or with customers and works backwards

Question 6

JIT Manufacturing : small lot sizes and quick setups

Answer 6

• Make products in small batches to reduce inventory and detect problems faster.
👉Small lots mean less average inventory and shorten manufacturing lead time.

•	Use quick setups so machines can switch between products easily. 👉 This gives more flexibility and less waste.

Question 7

JIT Manufacturing : Uniform Plant Loading

Answer 7

• Spread production evenly across time instead of in big bursts.

• A “level” schedule is developed so that the same mix of products is made every day in small quantities.

👉 Keeps workload smooth, avoids bottlenecks, and stabilizes schedules.

Question 8

JIT Manufacturing : Flexible Resources

Answer 8

• Use multi-skilled workers and machines that can do more than one job.
👉 Makes it easier to adjust to changes in demand.

Moveable, general-purpose equipment & Multifunction workers

Question 9

JIT Manifacturing : Facility Layout

Answer 9

• Arrange machines and workstations in the sequence of production (often U-shaped cells).
👉 Improves flow, reduces movement, and makes problems visible.

•Often use: Cell manufacturing, U-Shaped Lines
.

Question 10

6 Benefits of JIT System

Answer 10

1. Reduction in inventory and space requirements; lower production costs
   2. Less waste, better machine utilization – fewer excess materials and products.
   3. Better quality – problems are spotted quickly because items aren’t stockpiled.
   4. Faster response – production adjusts quickly to customer demand.
   5. Stronger supplier relationships – close coordination is needed for timely deliveries.
   6. Increase flexibility, productivity

Question 11

Push vs Pull Production Systems

Answer 11

PUSH: • Work is “pushed” forward based on forecasts or schedules, whether the next step needs it or not.
• Often creates extra inventory : products made in advance and stored in anticipation of demand.

PULL: •Work is “pulled” forward only when the next step or customer requests it.
•Reduces waste and excess inventory

👉 In short:
• Push = make to forecast (supply-driven).
• Pull = make to demand (customer-driven).

Question 12

Relationship between JIT and lean systems ?

Answer 12

A broad JIT view that encompasses the entire organization = lean systems

• Lean systems are a broader philosophy that aims to eliminate all forms of waste and improve value for the customer.

Question 13

JIT and…

1. Accounting
2. Marketing
3. Finance
4. Information Systems

Answer 13

1- Accounting to use activity-based costing (ABC) to allocate overhead.

2- MKT focuses on customer driven quality

3- Finance approves and evaluates financial investments / measures performance

4- Information systems create the network of information necessary for JIT to function.

👉 In short: JIT means every department focuses on reducing waste, improving flow, and working closely together.

Question 14

4 Types of waste

Answer 14

1. Material
2. energy
3. Time
4. Space

Question 15

JIT manufacturing : master production schedule

Answer 15

• statement of which products/quantities will be made in specific time periods

Question 16

Internal vs external setups

Answer 16

Internal setups : requires machine to be stopped

External setup: can be performed while machine is still running