CIM Lean Inventory & JIT Systems 2 — Questions and Answers
Question 1: Which lean concept focuses on producing only what is needed, when it is needed, and in the amount needed?
- Economic Order Quantity
- Just-In-Time production (Correct answer)
- Safety stock optimization
- Batch processing
Correct answer: Just-In-Time production
JIT production eliminates overproduction waste by synchronizing output precisely with demand.
Question 2: A company reduces its supplier base from 50 to 10 strategic partners. What lean benefit does this primarily achieve?
- Lower per-unit purchase price
- Stronger supplier relationships enabling JIT replenishment (Correct answer)
- Reduced freight costs per shipment
- Simplified accounts payable processing
Correct answer: Stronger supplier relationships enabling JIT replenishment
Fewer, trusted suppliers enable the frequent, reliable deliveries essential for JIT inventory systems.
Question 3: What is 'poka-yoke' and how does it relate to lean inventory management?
- A Japanese scheduling method that balances production flow
- An error-proofing device that prevents defects before they create scrap inventory (Correct answer)
- A visual management system using colored bins
- A demand forecasting technique for JIT purchasing
Correct 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.
Question 4: In a lean environment, 'takt time' is calculated as:
- Total production time divided by number of workers
- Available production time divided by customer demand rate (Correct answer)
- Cycle time multiplied by number of workstations
- Order lead time divided by batch size
Correct answer: Available production time divided by customer demand rate
Takt time sets the production pace that matches customer demand, preventing both overproduction and underproduction.
Question 5: Which of the following best describes 'heijunka' in lean production?
- Continuous improvement through small incremental changes
- Production leveling that smooths output volume and mix over time (Correct answer)
- Immediate stoppage of production when a defect is detected
- Visual signaling system for inventory replenishment
Correct 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.
Question 6: A manufacturer using JIT experiences a supplier delivery failure. What is the most likely immediate consequence?
- Higher carrying costs for excess inventory
- Production line stoppage due to material shortage (Correct answer)
- Increased scrap rates from rushed production
- Lower customer service levels from delayed shipping
Correct 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.
Question 7: What does 'single-piece flow' mean in lean manufacturing?
- Processing items one unit at a time through each production step without batching (Correct answer)
- Delivering raw materials in single truckload shipments
- Using one supplier for each component type
- Producing one product model per production line
Correct 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.
CIM Lean Inventory & JIT Systems 2
Which lean concept focuses on producing only what is needed, when it is needed, and in the amount needed?