JIT, Push/Pull, Mixed Model Scheduling, Kanban

Push/Pull Systems
Which of the statements about a Pull System is true?

A Pull system uses Materials Resource Planning (MRP) to schedule the release of work
based on actual or forecasted demand.

A Pull system limits the amount of WIP that can accumulate in a production system.

A Pull system does not control the amount of inventory in a production system.

Just-In-Time
Which of the following concepts is used for Just-In-Time production implementation?

Kanban

Six Sigma

5 WHYS

5S

MRP

Just-In-Time
The following are true about Just-In-Time production EXCEPT

Just-In-Time production is one of the key elements of quantity control in Lean Production

Just-In-Time production seeks to reduce any additional inventory in the system, not only
from the end products, but upstream in the progress, including Work-In-Progress (WIP) and
buffer stocks.

Just-In-Time production is best effected by implementing a Push-system for production.

Just-In-Time production requires a very stable production system: continuous flow

(reduce Mura) without excessive burden (Muri)

Pull Systems: Material Requests and Scheduling

Look at the process visualized below. In a Pull system, what do the material requests
imply for the schedule? Choose one answer only.
 The schedule for step 3 will be based on the request from step 2

The schedule for step 3 will be based on the request from step 1

The schedule for step 1 will be based on the request from step 2

The schedule for step 2 will be based on the request from step 1

Pull Systems: Processing Authorization

Look at the production system below. In a Pull system, which of the following
conditions would be a valid reason for Step 1 to start processing? (Assume that Step
1 has enough input material to start processing.)

When material for Step 2 is withdrawn from the inventory and a signal is sent back to
Step 1 to authorize production.

As soon as the demand arrives to Step 3

In a Pull system, Step 1 will always start processing first.

The Heijunka Approach for Mixed-Model Scheduling

According to the lecture, which of the following statements about the Heijunka
approach on Mixed-Model Scheduling is correct?

The units are sequenced as uniformly as possible based on the proportionate demand.

In the Heijunka approach units are sequenced as randomly as possible, keeping in mind
the end-of-month production targets.

The production should be kept inflexible so that only large batches can be produced.

Heijunka: Calculating Takt Times

Consider the following situaion:

- Demand is 9000 units per month.

- There are 20 working days per month.

- There are 2 shifts per day,

- and 8 hours per shift

Please calculate the takt time and choose the correct answer.

2.13 minutes

0.47 minutes

2.25 minutes

0.94 minutes

Please calculate the flow rate in units/min and choose the correct answer.

2.13 units/min

0.47 units/min

0.65 units/min

0.94 units/min

Heijunka: Calculating Proportionate Demand

We now expand the above questions as follows: e:

Of the 9000 units demanded per month:

2250 are Type A,

2250 are type B,

and 4500 are type C.

What is the proportionate demand of each type?

Part A: 33.33%, Part B: 33.33%, Part C: 33.33%

Part A: 50%, Part B: 25%, Part C: 25%

Part A: 25%, Part B: 25%, Part C: 33%

Part A: 25%, Part B: 25%, Part C: 50%

Heijunka: Final Flow Rates

If, for these 9000 units produced

2250 are Type A,

2250 are type B,

4500 are type C ,

the production sequencing used is

C-A-C-B-C-A-C-B-C-A-C-B

The time frame remains the same:

- 20 working days per month

- 2 shifts per day

- 8 hours per shift

What is the rate of production, on average, for each particular type?

Part A: 8.53 min, Part B: 8.53 min, Part C: 4.27 min

Part A: 2.13 min, Part B: 4.27 min, Part C: 8.53 min

Part A: 8.53 min, Part B: 4.27 min, Part C: 4.27 min

Part A: 2.13 min, Part B: 2.13 min, Part C: 2.13 min

Kanban Systems - Description
Please choose the correct statement about inventory control in a Kanban system from
below. Choose one answer only.

Simple to administer, stocks cannot accumulate.

Simple to administer, as stocks accumulate continuously.

There can always be more inventory between two resources than what has been
authorized by the kanban cards.

A specific number of containers and kanbans is used: start low, increase gradually.

Kanban Systems
You have to give a lecture on how a Kanban works. You have put together a slide for
each step, but you dropped the slides on the floor and they are out of order! Oh no!

Please sort the steps (A) - (E) for describing a Kanban system into the correct order,
referring to the process flow shown.

Choose the correct order of the slides from the choices here:

A) This Kanban card then gives the authorization for Step 2 to produce the
requested parts.

B) This means that step 3 sends a signal to step 2 to initiate replenishment.

C) As soon as step 3 has removed all material from its incoming inventory, it sends a
material request to step 2.

D) This is done by posting the Kanban card of the product withdrawn from stock from
step 3 to step 2.

Kanban works in this order: C-B-D-A

Kanban works in this order: A-B-D-C

Kanban works in this order: D-C-A-B

Kanban Rules
In the following you are presented some rules. Please choose TRUE, if this is a
correct rule for Kanban systems, and FALSE if it is not.
1. The following is a rule of Kanban systems: The receiving process withdraws from
the sending process - the sending process never delivers to the receiving process.

TRUE

FALSE
2.The following is a rule of Kanban systems: The quantity of parts produced is always higher
than the quantity of parts withdrawn and marked on the kanban card.

TRUE

FALSE
3. The following is a rule of Kanban systems: In case of urgent material requests, parts can
be produced or moved without a kanban card.

TRUE

FALSE