Kaizen
What is Kaizen?
Continuous improvement through small, incremental changes in production or processes.
Which of the following best describes cell production?
A) Workers complete only one repetitive task
B) Teams complete an entire product or part of it
C) Machines run automatically with no workers
D) Stock is delivered only when needed
B
JIT aims to reduce the need for ________ by delivering materials only when required.
Stock / inventory storage
What is overproduction?
Producing more goods than the business can sell or use.
Give two benefits of Kaizen for a business.
Reduces waste; improves efficiency and productivity.
Give one reason why Kaizen requires strong communication between managers and workers.
Workers need to share improvement ideas and managers must act on them for real change to happen.
How does JIT help improve a company’s cash flow?
Money isn’t tied up in stock; less spent on storage and warehousing.
Give two ways overproduction increases costs.
Increases storage and holding costs; wastes materials and labor; may require discounting unsold goods.
How does Kaizen involve workers?
Employees are encouraged to suggest improvements, increasing responsibility and engagement.
Give two ways cell production benefits a business.
Improves quality; allows faster problem-solving; increases flexibility.
A shop orders stock only when current stock is almost sold out. Explain one advantage of this.
Less money is tied up in stock, reducing storage costs and improving cash flow.
A bakery produces 500 cakes but sells only 350. What problems does this cause?
150 cakes are wasted, increasing costs for ingredients, labor, and storage.
A factory encourages weekly suggestions, but few employees participate. Explain why participation might be low and how management can improve it.
Low participation may be due to fear of criticism, lack of confidence, or no incentives. Management can provide training, recognition, or rewards.
A furniture factory organizes teams to assemble entire pieces rather than just parts. Explain why this can reduce errors and improve quality.
Workers can see the entire product, notice mistakes earlier, and correct them immediately, reducing defects and improving quality.
Name two risks of using JIT and explain their effects.
Supplier delays → production stops; unexpected demand → unable to meet orders quickly. Both can disrupt operations.
How can overproduction affect customer satisfaction?
Products may become stale or outdated; quality may decrease; customers may lose trust.
Suggest two strategies to implement Kaizen successfully across all departments.
Hold regular improvement meetings; train employees in improvement methods; reward or recognize suggestions.
Workers can see the entire product, notice mistakes earlier, and correct them immediately, reducing defects and improving quality.
Reason 1: Workers inexperienced → Solution: training; Reason 2: Poor cell layout → Solution: reorganize workflow.
A manufacturer using JIT faces a supplier delay. Suggest two strategies to continue production without holding large stock.
Use alternative suppliers; prioritize production of critical products; adjust production schedule to available materials.
Name two lean production methods that prevent overproduction and explain how they work.
Just-in-Time – produces only what is needed when needed; Cell Production – balances output to demand and reduces unnecessary stock.