CPIM Lean Manufacturing and Just-In-Time (JIT) Principles 1 — Questions and Answers
Question 1: Which of the following best describes the primary goal of a Just-In-Time (JIT) production system?
- Maximize batch sizes to reduce per-unit costs
- Produce and deliver items only when needed in the quantities needed (Correct answer)
- Maintain large safety stocks to prevent stockouts
- Increase machine utilization rates above 95%
Correct answer: Produce and deliver items only when needed in the quantities needed
JIT aims to produce and deliver the right items in the right quantity at the right time, eliminating waste from overproduction and excess inventory.
Question 2: In lean terminology, which Japanese term refers to the relentless pursuit of waste elimination and continuous improvement?
- Kanban
- Kaizen (Correct answer)
- Poka-yoke
- Heijunka
Correct answer: Kaizen
Kaizen means 'change for better' and represents the lean philosophy of continuous, incremental improvement involving all employees.
Question 3: The seven wastes (muda) identified in the Toyota Production System do NOT include which of the following?
- Overproduction
- Waiting
- Strategic planning (Correct answer)
- Defects
Correct answer: Strategic planning
The seven wastes are overproduction, waiting, transportation, over-processing, inventory, motion, and defects — strategic planning is a management activity, not a waste category.
Question 4: A kanban card system is primarily used to:
- Schedule preventive maintenance on equipment
- Signal the need to replenish or produce a specific quantity of an item (Correct answer)
- Track employee performance metrics
- Manage supplier contracts and pricing
Correct answer: Signal the need to replenish or produce a specific quantity of an item
Kanban cards serve as visual signals that authorize and trigger the replenishment or production of a set quantity of parts or materials.
Question 5: Which lean concept involves leveling production volume and mix over a planning period to reduce variability?
- Poka-yoke
- Heijunka (Correct answer)
- Jidoka
- Gemba
Correct answer: Heijunka
Heijunka is the practice of leveling the type and quantity of production over a fixed time period to reduce unevenness (mura) and overburden (muri).
Question 6: What is the concept of 'takt time' in lean manufacturing?
- The time required to set up a machine for a new production run
- The average time available per unit to match production rate to customer demand (Correct answer)
- The total lead time from raw material to finished goods
- The time between scheduled preventive maintenance intervals
Correct answer: The average time available per unit to match production rate to customer demand
Takt time is calculated as available production time divided by customer demand rate, setting the pace at which products must be completed to satisfy demand.
Question 7: In a lean pull system, production is triggered by:
- A master production schedule pushed from planning
- Actual downstream consumption or customer demand signals (Correct answer)
- Supplier delivery schedules and lead times
- Management forecasts of future demand
Correct answer: Actual downstream consumption or customer demand signals
In a pull system, each production stage is triggered only when the downstream stage signals a need, ensuring work is produced in response to actual demand rather than forecasts.
CPIM Lean Manufacturing and Just-In-Time (JIT) Principles 1
Which of the following best describes the primary goal of a Just-In-Time (JIT) production system?