Lean Inventory & JIT Systems Flashcards

The '5S' methodology in lean includes Sort, Set in Order, Shine, Standardize, and:

Answer: Sustain

Sustain (Shitsuke) ensures the 5S discipline is maintained over time through training and audits rather than reverting to old habits.

Which waste category in the Toyota Production System refers to excess inventory beyond immediate production needs?

Answer: Inventory waste

Inventory waste (one of the seven muda) specifically covers any stock beyond the minimum needed to keep production flowing.

A lean team conducts a 'gemba walk.' What is the primary purpose of this activity?

Answer: Going to the actual workplace to observe real processes and identify waste

Gemba walks involve direct observation at the point of work to see waste and inefficiencies that data reports often miss.

In lean inventory thinking, which condition justifies holding safety stock?

Answer: Demand variability or supply uncertainty that cannot yet be eliminated

Safety stock is a temporary buffer for variability; lean aims to reduce variability so safety stock can eventually be minimized.

What is the main difference between 'push' and 'pull' production systems?

Answer: Push systems produce based on forecasts; pull systems produce only in response to actual demand

Pull systems replenish only what has been consumed, eliminating the forecast-driven overproduction that generates excess inventory.

Which metric best measures the effectiveness of a JIT inventory system?

Answer: Inventory turnover ratio

High inventory turnover indicates stock is moving quickly through the system with minimal time spent sitting idle, which is the hallmark of JIT.

A value stream map (VSM) reveals that 90% of a product's lead time is spent waiting between process steps. What lean action is most appropriate?

Answer: Redesign the flow to enable single-piece flow and eliminate waiting

VSM exposes non-value-added waiting time; the lean response is to redesign flow so parts move immediately from step to step.