Deck 17: Lean Operating Systems

Question 1

Drive-in-Style Motors follows a traditional manufacturing system. It produces a fixed number of cars every month. It is now planning to switch to a system of manufacturing where workers go to the source of required parts and withdraw them based on requirements. In this scenario, which of the following is most likely to occur if Drive-in-Style Motors implements this plan

A) Its inventory levels will increase significantly when the demand is low.
B) Its component parts and subassemblies will be replenished only when needed.
C) Its finished goods inventory will decrease, but raw materials and work-in-process inventories will increase.
D) Its workers, at any given process, will produce units before they are needed.

Answer 1

Its component parts and subassemblies will be replenished only when needed.

Question 2

A hinge manufacturing company employs a Kanban system for a component part. The daily demand is 900 hinges. Each container has a waiting time of 0.05 days and a processing time of 0.37 days. The container size is 60 hinges, and the safety factor (α) is 10 percent. Given this data, the number of Kanbans necessary for the system is:

A) less than 4 Kanbans.
B) more than 4 but less than or equal to 8 Kanbans.
C) more than 8 but less than or equal to 12 Kanbans.
D) more than 12 but less than or equal to 16 Kanbans.

Answer 2

more than 4 but less than or equal to 8 Kanbans.

Question 3

Lean Six Sigma focuses on real dollar savings and has the ability to make significant financial impacts on an organization.

Answer 3

True

Question 4

__________is focused on ensuring that operating systems will perform their intended function reliably.

A) Total productive maintenance
B) A just-in-time system
C) An intermittent production system
D) Total quality management

Question 5

Any activity, material, or operation that does not add value in an organization is considered waste.

Question 6

The equation used to calculate the number of Kanban cards required in a system is , where denotes _____.

A) the demand during lead time
B) a form of safety stock
C) capacity utilization
D) the reorder point

Question 7

A__________produces finished-goods inventory in advance of customer demand using a forecast of sales.

A) just-in-time system
B) push system
C) Kanban system
D) pull system

Question 8

In the context of the 5S principles, _____ refers to ensuring that each item in a workplace is in its proper place or identified as unnecessary and removed.

A) sort
B) sustain
C) standardize
D) set in order

Question 9

A manufacturer of automobile engines is designing a new Kanban system for engine #321. The demand for #321 is 75 parts per day, and the container can hold 8 parts at a time. The total processing and waiting time is 3 days. The manager wants a safety factor ( α ) of 2 or 200 percent. How many Kanbans are required in this system

A) 85
B) 90
C) 100
D) 115

Question 10

Total productive maintenance (TPM) seeks to reduce worker ownership of production equipment by excluding employees from maintenance activities.

Question 11

Which of the following is an example of waste in organizations

A) Short order-cycle time
B) Routing a job
C) Planned product obsolescence
D) High product variety

Question 12

In the context of lean tools and approaches,__________, one of the components of the 5S principles, refers to a clean work area.

A) shine
B) standardize
C) sort
D) sustain

Question 13

In the context of the 5S principles, _____ means to keep a process going through training, communication, and organizational structures.

A) shine
B) sort
C) sustain
D) standardize

Question 14

_____ is one in which employees at a given operation go to the source of required parts, such as machining or subassembly, and withdraw the units as they need them.

A) A classic base-stock system
B) A push system
C) A materials requirement planning system
D) A pull system

Question 15

Create & Sell Manufacturing Inc. uses a Kanban system for a component. The daily demand is 175 units. Each container has a combined waiting and processing time of 0.20 days. If the container size is 10 brackets and the safety factor is 11 percent, how many Kanban card sets should be authorized

A) 2
B) 4
C) 6
D) 7

Question 16

In the context of Kanban systems, a withdrawal Kanban authorizes the gateway workstation to produce parts.

Question 17

In the context of the major categories of waste classified by the Toyota Motor Company, which of the following is true of overproduction

A) It ties up production facilities, and the resulting excess inventory simply sits idle.
B) It is waste associated with the expense of idle stock and extra storage.
C) It allows queues to build up between operations, resulting in longer lead times.
D) It is a result of inefficient workplace design and location of tools and materials.

Question 18

Long setup times enable a manufacturer to have frequent changeovers and move toward single-piece flow, thus achieving high flexibility and product variety.

Question 19

Which of the following is true of a push manufacturing system

A) It leads to high work-in-process inventories and high levels of indirect labor and overhead.
B) In this system, just enough new parts are procured to replace those withdrawn.
C) In this system, finished goods are made to coincide with the actual rate of demand.
D) It leads to minimal inventories and maximum responsiveness.

Question 20

Kanban is a Japanese word that means elimination of waste.

Question 21

Which of the following is a difference between lean production and Six Sigma

A) The lean production technique can be used in nonmanufacturing environments, whereas Six Sigma cannot be used in nonmanufacturing environments.
B) Lean production addresses less visible problems in processes, whereas Six Sigma is more concerned with visible problems.
C) Lean production is focused on effectiveness by reducing errors and defects, whereas Six Sigma is focused on efficiency by reducing waste and improving process flow.
D) Lean production tools are more intuitive and easier to apply by anybody in the workplace, whereas many Six Sigma tools require advanced training and expertise of specialists.

Question 22

A__________is a flag or a piece of paper that contains all relevant information for an order, such as part number, description, process area used, time of delivery, quantity available, quantity delivered, production quantity, and so on.

A) Kaikaku
B) Jidoka
C) Kaizen
D) Kanban

Question 23

In the context of lean tools and approaches, _____ are indicators for operating activities that are placed in plain sight of all employees so that everyone can quickly and easily understand the status and performance of the work system.

A) Kanban cards
B) push systems
C) pull systems
D) visual controls

Question 24

In the context of the 5S principles,__________means to arrange materials and equipment so that they are easy to find and use.

A) shine
B) standardize
C) sustain to produce
D) set in order

Question 25

Which of the following is a similarity between lean production and Six Sigma

A) Both solely address visible problems in processes.
B) Both focus on efficiency by reducing waste and improving process flow.
C) Both are driven by customer requirements.
D) Both focus on problems related to variation in performance.

Question 26

A company is using a Kanban system with 2 containers, each holding 50 parts, between a downstream (using) and an upstream (producing) work center. The using work center can handle 250 jobs per day. The average elapsed time for the entire cycle is currently 0.25 days. The company is concerned about the safety factor for the operation. Which of the following is the safety factor (α) of the current operation

A) 20 percent
B) 60 percent
C) 80 percent
D) 40 percent