Lean Inventory & JIT Systems Flashcards

Which lean concept focuses on producing only what is needed, when it is needed, and in the amount needed?

Answer: Just-In-Time production

JIT production eliminates overproduction waste by synchronizing output precisely with demand.

A company reduces its supplier base from 50 to 10 strategic partners. What lean benefit does this primarily achieve?

Answer: Stronger supplier relationships enabling JIT replenishment

Fewer, trusted suppliers enable the frequent, reliable deliveries essential for JIT inventory systems.

What is 'poka-yoke' and how does it relate to lean inventory management?

Answer: An error-proofing device that prevents defects before they create scrap inventory

Poka-yoke devices mistake-proof processes, preventing defective items from becoming waste inventory that must be scrapped or reworked.

In a lean environment, 'takt time' is calculated as:

Answer: Available production time divided by customer demand rate

Takt time sets the production pace that matches customer demand, preventing both overproduction and underproduction.

Which of the following best describes 'heijunka' in lean production?

Answer: Production leveling that smooths output volume and mix over time

Heijunka levels production to avoid the peaks and valleys that force excess inventory buffers.

A manufacturer using JIT experiences a supplier delivery failure. What is the most likely immediate consequence?

Answer: Production line stoppage due to material shortage

JIT systems carry minimal buffer stock, so supplier failures directly halt production with no safety stock to absorb the disruption.

What does 'single-piece flow' mean in lean manufacturing?

Answer: Processing items one unit at a time through each production step without batching

Single-piece flow eliminates work-in-process inventory between operations by moving one unit at a time rather than batches.