Deck 15: Lean Production

Question 1

Linearity in a lean environment means:

A) produce small lot sizes
B) plan level schedules
C) each day achieve the plan, no more or less
D) eliminate all idle time
E) statistical process control

Answer 1

C

Question 2

Reduced setup has which of the following advantages?
I) Reduced lot sizes.
II) Reduce lead time and queue.
III) Improved quality.

A) all the above
B) I and II only
C) I and III only
D) II and III only
E) I only

Answer 2

A

Question 3

Which of the following statements is true?
I) Value starts in the marketplace.
II) Cost and value are the same thing.
III) Counting and storing add value to the product.

A) I and II
B) I and III
C) II and III
D) I
E) III

Answer 3

D

Question 4

Overproduction causes waste by:

A) consuming unneeded raw materials and labor
B) creating excess inventory
C) causing confusion and hiding problems
D) a and b
E) all the above

Question 5

A pull system is developed to provide which of the following?

A) an alternative to a classic MRP system
B) to provide only what is needed and when it is needed
C) only used when demand is constant and known
D) only used when demand is unknown

Question 6

The buyer expects that a supplier will provide each of the following EXCEPT:

A) the quality needed at all times
B) information on competitors
C) frequent deliveries
D) improved quality and cost

Question 7

An example of using the poka-yoke technique in process design is

A) Reducing the number and type of fasteners
B) Using standardized tooling
C) Using tooling to prevent a part from being inserted upside down
D) Eliminating bill of material levels

Question 8

Which of the following statements is best?
I) Lean and manufacturing planning and control cannot work together.
II) The lean philosophy simplifies and reduces manufacturing planning and control problems.
III) Lean requires a very good planning and control system.

A) all the above are true
B) I and II
C) I and III
D) II and III
E) none of the above

Question 9

If a company standardizes on the components that are used in different models it will:

A) reduce waste
B) reduce the variety of options offered to the customer
C) reduce the length of production runs
D) require the use of general-purpose machinery

Question 10

Which of the following statements is best regarding lean production?
I) It is a philosophy that relates to the way in which a manufacturing company organizes and operates its business.
II) It is a set of techniques to make manufacturing more productive.
III) It is concerned with adding value to the product.

A) all the above are true
B) I and II are best
C) I and III are best
D) II and III are best
E) I only is best

Question 11

Which of the following contribute to machine flexibility?

A) small general-purpose machinery
B) mobility of machines
C) automated high-capacity machines
D) a and b above
E) b and c above

Question 12

Which of the following are advantages of reducing inventory?
I) Engineering changes can be made sooner.
II) Quality can be improved.
III) Less space is needed in manufacturing.
IV) Lead time will be shorter.

A) all the above
B) only I, II and III
C) only I, II and IV
D) only II, III and IV
E) only III and IV

Question 13

Lean practices will change the material requirements planning process by:

A) reducing the number of levels in the bill of material
B) making the bill of material more complex
C) increasing the need for offsetting
D) increasing the need for netting
E) eliminating the need for MRP

Question 14

Lean production will influence master production scheduling by:

A) reducing time fences and making the MPS more responsive to customer demand
B) making it possible to use daily time buckets
C) making the MPS more unstable
D) a and b only
E) b and c only

Question 15

Which of the following concepts is needed to achieve uninterrupted material flow?

A) uniform plant loading
B) pull system
C) valid schedules
D) all the above are needed
E) a and b only are needed

Question 16

Employee involvement in a lean environment means:
I) Operators must take responsibility for improving the process.
II) Management must take more of a leadership role.
III) Staff must be trainers and assist line people.

A) all the above
B) I and II only
C) I and III only
D) II and III only
E) none of the above

Question 17

The ideal product is one that:
I) Meets or exceeds the needs of the customer.
II) Makes the best use of material.
III) Can be manufactured at least cost.

A) all the above
B) I and II only
C) II and III only
D) I only

Question 18

Which of the following is a benefit to the purchaser in supplier partnerships?

A) frequent deliveries on a just-in-time basis
B) better quality
C) improved performance and cost
D) all the above
E) a and b above only

Question 19

Which of the following is NOT an advantage of work cells?

A) queue and lead time are reduced
B) production activity control is simplified
C) need for floor space is reduced
D) immediate feedback
E) maximum machine utilization

Question 20

Which of the following statements is best about quality?
I) Quality can be inspected into a product.
II) Poor quality has no effect on work flow.
III) The process must be capable of producing the required quality consistently.
IV) Machinery must be maintained in excellent condition.

A) all the above
B) I and II only
C) II and III only
D) III and IV only
E) I and IV only

Question 21

The term that describes eliminating waste throughout a company is:

A) Kaizen
B) Lean Production
C) Theory of Constraints
D) Process Control

Question 22

Which of the following techniques reduces the cost of processing transactions?

A) Backflushing
B) Pareto analysis
C) Mean absolute deviation
D) SMED

Question 23

Which of the following terms refers to a pull system in which signals are used to withdraw parts from feeding operations or suppliers?

A) Andon
B) Kanban
C) Dispatching
D) Poka-yoke

Question 24

Which of the following define the 5S approach to housekeeping?

A) Sort, Straighten, Safety, Schedule, Source
B) Straighten, Shine, Standardize, Source, Smooth
C) Sort, Straighten, Shine, Standardize, Sustain
D) Shine, Standardize, Sustain, Schedule, Smooth

Question 25

Employee participation in small, incremental improvements is known as:

A) Value stream mapping
B) Drum-buffer-rope
C) Kaizen
D) Motion economy

Question 26

Bills of material used for MRP planning in a lean environment are likely to have which of the following characteristics?

A) fewer "phantom" or "blow-through" assemblies
B) increased complexity with regard to options
C) weekly time buckets
D) no need for where-used references
E) fewer levels in product structures

Question 27

Matching the pace of production to match the rate of customer demand is known as:

A) Poka-yoke
B) Drum-buffer-rope
C) Bullwhip
D) Takt time