CIM Lean Inventory & JIT Systems 4 — Questions and Answers
Question 1: Which of the following is a key prerequisite for successfully implementing JIT inventory?
- Large warehouse capacity to hold emergency stock
- Reliable, high-quality suppliers capable of frequent small deliveries (Correct answer)
- Advanced demand forecasting software
- High product standardization with few SKU variants
Correct answer: Reliable, high-quality suppliers capable of frequent small deliveries
JIT depends entirely on suppliers delivering defect-free materials on time in small quantities, making supplier reliability non-negotiable.
Question 2: What is 'andon' in the context of lean manufacturing?
- A scheduling algorithm that sequences jobs by due date
- A visual signal system that alerts the team to a production problem so it can be addressed immediately (Correct answer)
- A supplier rating system based on on-time delivery
- A WIP tracking dashboard updated in real time
Correct answer: A visual signal system that alerts the team to a production problem so it can be addressed immediately
Andon systems (lights, cords, or boards) make problems visible instantly so teams can swarm and resolve them before defects or downtime propagate.
Question 3: A company implements SMED (Single-Minute Exchange of Die). What inventory impact does this have?
- Increases minimum order quantities from suppliers
- Allows economical small-batch production, reducing WIP and finished goods inventory (Correct answer)
- Reduces the number of SKUs needed in the product line
- Enables longer production runs that lower per-unit cost
Correct answer: Allows economical small-batch production, reducing WIP and finished goods inventory
SMED slashes changeover time, making small production runs economical and eliminating the large batch sizes that create excess inventory.
Question 4: In lean terminology, what is a 'supermarket' in the context of pull systems?
- A supplier that stocks a broad catalog of parts
- A controlled inventory point where items are stored for downstream processes to pull as needed (Correct answer)
- A retail distribution center using lean replenishment
- A software module that manages kanban card circulation
Correct answer: A controlled inventory point where items are stored for downstream processes to pull as needed
A lean supermarket is a small, managed buffer between disconnected processes that enables pull replenishment when true continuous flow isn't possible.
Question 5: Which lean waste category describes unnecessary movement of inventory or materials within a facility?
- Motion (worker movement)
- Transportation (material movement) (Correct answer)
- Overprocessing
- Defects
Correct answer: Transportation (material movement)
Transportation waste involves moving materials farther or more often than necessary, which adds cost and risk of damage without adding value.
Question 6: A lean assessment finds that a plant produces 500 units/day but customers only demand 300 units/day. Which waste does this represent?
- Waiting
- Overproduction (Correct answer)
- Overprocessing
- Defects
Correct answer: Overproduction
Overproduction — making more than demand requires — is considered the worst lean waste because it generates inventory that hides other problems.
Question 7: What role does Total Productive Maintenance (TPM) play in supporting JIT inventory systems?
- TPM schedules planned downtime to prevent unplanned stoppages that would require safety stock
- TPM maximizes equipment availability and reliability, enabling consistent JIT production without buffer stock (Correct answer)
- TPM tracks spare parts inventory to ensure quick repairs
- TPM trains workers to perform quality inspections during production
Correct answer: TPM maximizes equipment availability and reliability, enabling consistent JIT production without buffer stock
Reliable equipment is a JIT prerequisite — TPM's focus on preventing breakdowns allows low-inventory systems to operate without costly production stoppages.
CIM Lean Inventory & JIT Systems 4
Which of the following is a key prerequisite for successfully implementing JIT inventory?