Deck 9: Lean Systems

Question 1

A lean system has the following characteristics: demand rate = 40 parts per hour; safety stock required = 10%; the container size = 8; lead time to replenish an order = 4 hours.

-How many containers should the system be using?

A)2
B)5
C)10
D)22
E)30

Answer 1

22

Question 2

A lean system has the following characteristics: demand rate = 40 parts per hour; safety stock required = 10%; the container size = 8; lead time to replenish an order = 4 hours.

-Calculate the maximum system inventory for this part.

A)16 units
B)40 units
C)240 units
D)80 units
E)176 units

Answer 2

176 units

Question 3

A lean system has the following characteristics: demand rate = 40 parts per hour; safety stock required = 10%; the container size = 8; lead time to replenish an order = 4 hours.

-If the number of containers is reduced by 2 units, what would be the new required round-trip time, all else being constant?

A)3.64 hours
B)3.83 hours
C)4 hours
D)4.4 hours
E)Need additional information to compute the value

Answer 3

3.64 hours

Question 4

A lean system has the following characteristics: demand rate = 40 parts per hour; safety stock required = 10%; the container size = 8; lead time to replenish an order = 4 hours.

-If the number of containers is increased by 2 units, what would be the new required safety stock, all else being constant?

A)10%
B)20%
C)0%
D)15%
E)Need additional information to compute the value

Question 5

A lean system has the following characteristics: demand rate = 40 parts per hour; safety stock required = 10%; the container size = 8; lead time to replenish an order = 4 hours.

-If the number of containers is decreased by 2 units, what would be the new required safety stock, all else being constant?

A)10%
B)20%
C)0%
D)15%
E)Need additional information to compute the value

Question 6

A lean system uses 12 containers, each of which can hold 12 parts. The lead time required to round-trip one container through the system is normally 3 hours. The usual safety stock is 20%.

-What is the maximum demand rate this system can accommodate?

A)10 parts per hour
B)20 parts per hour
C)30 parts per hour
D)40 parts per hour
E)50 parts per hour

Question 7

A lean system uses 12 containers, each of which can hold 12 parts. The lead time required to round-trip one container through the system is normally 3 hours. The usual safety stock is 20%.

-Calculate the maximum system inventory for this part.

A)36 units
B)40 units
C)144 units
D)80 units
E)480 units

Question 8

A lean system uses 12 containers, each of which can hold 12 parts. The lead time required to round-trip one container through the system is normally 3 hours. The usual safety stock is 20%.

-If the demand rate is changed to 50 parts per hour, what would be the new container size, all else being constant?

A)12 parts
B)15 parts
C)10 parts
D)20 parts
E)Need additional information to compute the value

Question 9

A lean system uses 12 containers, each of which can hold 12 parts. The lead time required to round-trip one container through the system is normally 3 hours. The usual safety stock is 20%.

-If the demand rate is changed to 50 parts per hour, how many containers should the system be using, all else being constant?

A)10 containers
B)12 containers
C)15 containers
D)20 containers
E)Need additional information to compute the value

Question 10

A lean system uses 12 containers, each of which can hold 12 parts. The lead time required to round-trip one container through the system is normally 3 hours. The usual safety stock is 20%.

-If the demand rate is changed to 50 parts per hour, what would be the new required round-trip time, all else being constant?

A)2.4 hours
B)3 hours
C)3.75 hours
D)5 hours
E)Need additional information to compute the value

Question 11

An integrated electronic-chip manufacturer has a demand for a specific component of 800 parts per 8-hour day. The manufacturer wants to design a lean system using containers. The containers the manufacturer used for this component held 20 parts. It takes about 4 hours to round-trip a container from one work center to the next and back again. The manufacturer also wants to hold 10% of safety stock of this part in its system.

-How many containers should the lean system be using?

A)5
B)10
C)20
D)22
E)30

Question 12

An integrated electronic-chip manufacturer has a demand for a specific component of 800 parts per 8-hour day. The manufacturer wants to design a lean system using containers. The containers the manufacturer used for this component held 20 parts. It takes about 4 hours to round-trip a container from one work center to the next and back again. The manufacturer also wants to hold 10% of safety stock of this part in its system.

-Calculate the maximum system inventory for this part.

A)88 units
B)400 units
C)240 units
D)800 units
E)440 units

Question 13

An integrated electronic-chip manufacturer has a demand for a specific component of 800 parts per 8-hour day. The manufacturer wants to design a lean system using containers. The containers the manufacturer used for this component held 20 parts. It takes about 4 hours to round-trip a container from one work center to the next and back again. The manufacturer also wants to hold 10% of safety stock of this part in its system.

-If the required safety stock was changed to zero, how many containers should the lean system be using, all else being constant?

A)5
B)10
C)20
D)22
E)30

Question 14

An integrated electronic-chip manufacturer has a demand for a specific component of 800 parts per 8-hour day. The manufacturer wants to design a lean system using containers. The containers the manufacturer used for this component held 20 parts. It takes about 4 hours to round-trip a container from one work center to the next and back again. The manufacturer also wants to hold 10% of safety stock of this part in its system.

-If the required safety stock were changed to zero and 20 containers were used in the system, calculate the maximum inventory for this part.

A)88 units
B)400 units
C)240 units
D)800 units
E)440 units

Question 15

An integrated electronic-chip manufacturer has a demand for a specific component of 800 parts per 8-hour day. The manufacturer wants to design a lean system using containers. The containers the manufacturer used for this component held 20 parts. It takes about 4 hours to round-trip a container from one work center to the next and back again. The manufacturer also wants to hold 10% of safety stock of this part in its system.

-Based on the required safety stock of zero and the number of containers computed in Question 13, what would be the new required round-trip time, all else being constant?

A)4.4 hours
B)4 hours
C)3.5 hours
D)5 hours
E)Need additional information to compute the value

Question 16

An integrated electronic-chip manufacturer has a demand for a specific component of 800 parts per 8-hour day. The manufacturer wants to design a lean system using containers. The containers the manufacturer used for this component held 20 parts. It takes about 4 hours to round-trip a container from one work center to the next and back again. The manufacturer also wants to hold 10% of safety stock of this part in its system.

-If the manufacturer reduced the number of containers from 22 to 21, what will be the safety stock, all else being constant?

A)5%
B)10%
C)15%
D)20%
E)25%

Question 17

Berlin Industries uses a kanban system to manage production of the R-15 subassembly. They have an hourly demand for 250 units and use containers that can hold 50 parts each. It takes 90 minutes to fill and move a container of parts to the right place on the R-15 line that is currently rated at a 20% safety factor.

-How many containers should the kanban system of Berlin Industries be using?

A)540
B)100
C)50
D)9
E)1.5

Question 18

Berlin Industries uses a kanban system to manage production of the R-15 subassembly. They have an hourly demand for 250 units and use containers that can hold 50 parts each. It takes 90 minutes to fill and move a container of parts to the right place on the R-15 line that is currently rated at a 20% safety factor.

-Calculate the maximum system inventory for this part.

A)450 units
B)400 units
C)2,500 units
D)5,000 units
E)75 units

Question 19

Berlin Industries uses a kanban system to manage production of the R-15 subassembly. They have an hourly demand for 250 units and use containers that can hold 50 parts each. It takes 90 minutes to fill and move a container of parts to the right place on the R-15 line that is currently rated at a 20% safety factor.

-If demand is expected to be double the rate planned earlier, how many containers should the kanban system be using?

A)18
B)540
C)100
D)9
E)50

Question 20

Berlin Industries uses a kanban system to manage production of the R-15 subassembly. They have an hourly demand for 250 units and use containers that can hold 50 parts each. It takes 90 minutes to fill and move a container of parts to the right place on the R-15 line that is currently rated at a 20% safety factor.

-If demand is expected to be double the rate planned earlier and with 18 containers, what will be the maximum inventory, all else being constant?

A)450 units
B)900 units
C)2,500 units
D)5,000 units
E)75 units

Question 21

Copenhagen Industries uses a kanban system to manage production of their subassembly. In a 10-hour day, they use 1,500 units and use containers that can hold 50 units each. It takes 45 minutes to fill and move a container of parts to the right place on the subassembly line that is currently rated at a 15% safety factor.

-How many containers should the kanban system of Copenhagen Industries be using?

A)26
B)82
C)155
D)9
E)3

Question 22

Copenhagen Industries uses a kanban system to manage production of their subassembly. In a 10-hour day, they use 1,500 units and use containers that can hold 50 units each. It takes 45 minutes to fill and move a container of parts to the right place on the subassembly line that is currently rated at a 15% safety factor.

-Calculate the maximum system inventory for this part.

A)4,100 units
B)400 units
C)150 units
D)5,000 units
E)1,300 units

Question 23

Copenhagen Industries uses a kanban system to manage production of their subassembly. In a 10-hour day, they use 1,500 units and use containers that can hold 50 units each. It takes 45 minutes to fill and move a container of parts to the right place on the subassembly line that is currently rated at a 15% safety factor.

-If the required safety stock was changed to zero, how many containers should the lean system be using, all else being constant?

A)26
B)82
C)155
D)9
E)3

Question 24

Copenhagen Industries uses a kanban system to manage production of their subassembly. In a 10-hour day, they use 1,500 units and use containers that can hold 50 units each. It takes 45 minutes to fill and move a container of parts to the right place on the subassembly line that is currently rated at a 15% safety factor.

-If the required safety stock was changed to zero and 3 containers were being used in the system, calculate the maximum inventory.

A)4,100 units
B)400 units
C)150 units
D)5,000 units
E)1,300 units

Question 25

Copenhagen Industries uses a kanban system to manage production of their subassembly. In a 10-hour day, they use 1,500 units and use containers that can hold 50 units each. It takes 45 minutes to fill and move a container of parts to the right place on the subassembly line that is currently rated at a 15% safety factor.

-If the required round-trip time is changed to 1 hour, how many containers should the lean system be using, all else being constant?

A)15
B)20
C)10
D)9
E)5

Question 26

Istanbul Industries uses a kanban system to manage production of the MI6 subassembly. In an 8-hour day, they use 100 units per hour and use containers that can hold 23 units each. It takes 120 minutes to fill and move a container of parts to the right place on the MI6 line that is currently rated at a 15% safety factor.

-How many containers should the kanban system of Istanbul Industries be using?

A)10
B)15
C)20
D)25
E)30

Question 27

Istanbul Industries uses a kanban system to manage production of the MI6 subassembly. In an 8-hour day, they use 100 units per hour and use containers that can hold 23 units each. It takes 120 minutes to fill and move a container of parts to the right place on the MI6 line that is currently rated at a 15% safety factor.

-Calculate the maximum system inventory for this part.

A)345 units
B)690 units
C)460 units
D)230 units
E)575 units

Question 28

Istanbul Industries uses a kanban system to manage production of the MI6 subassembly. In an 8-hour day, they use 100 units per hour and use containers that can hold 23 units each. It takes 120 minutes to fill and move a container of parts to the right place on the MI6 line that is currently rated at a 15% safety factor.

-If the number of containers is reduced by 1, what would be the new required safety stock, all else being constant?

A)5%
B)3.5%
C)10%
D)12%
E)15%

Question 29

Istanbul Industries uses a kanban system to manage production of the MI6 subassembly. In an 8-hour day, they use 100 units per hour and use containers that can hold 23 units each. It takes 120 minutes to fill and move a container of parts to the right place on the MI6 line that is currently rated at a 15% safety factor.

-If the number of containers is reduced by 1, what would be the new required round-trip time, all else being constant?

A)90 minutes
B)1 hour
C)1.8 hours
D)2 hours
E)Need additional information to compute the value

Question 30

Istanbul Industries uses a kanban system to manage production of the MI6 subassembly. In an 8-hour day, they use 100 units per hour and use containers that can hold 23 units each. It takes 120 minutes to fill and move a container of parts to the right place on the MI6 line that is currently rated at a 15% safety factor.

-If the number of containers is reduced by 1, what would be the new demand, all else being constant?

A)100 units per hour
B)800 units for an 8-hour day
C)90 units for an 8-hour day
D)100 units for an 8-hour day
E)90 units per hour

Question 31

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-How many containers should the lean system be using?

A)5
B)10
C)15
D)20
E)25

Question 32

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-Calculate the maximum system inventory for this part.

A)250 units
B)50 units
C)100 units
D)200 units
E)150 units

Question 33

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-If the required safety stock was changed to zero, how many containers should the lean system be using, all else being constant?

A)10
B)13
C)15
D)20
E)25

Question 34

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-Based on the required safety stock of zero and the number of containers computed in Question 33, calculate the maximum inventory for this part.

A)250 units
B)100 units
C)150 units
D)130 units
E)200 units

Question 35

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-Based on the required safety stock of zero and the number of containers computed in Question 33, what would be the new required round-trip time, all else being constant?

A)4.4 hours
B)5.2 hours
C)6.6 hours
D)7.8 hours
E)8 hours

Question 36

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-Based on the required safety stock of zero and the number of containers computed in Question 33, what will be the demand for an 8-hour day, all else being constant?

A)240 parts
B)26 parts
C)208 parts
D)30 parts
E)200 parts

Question 37

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-If the container size from the original data was changed to 15, how many containers should the lean system be using, all else being constant?

A)10
B)13
C)15
D)20
E)25

Question 38

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-If the container size from the original data was changed to 15, and there were 10 containers in the system, what is the maximum inventory for this part?

A)250 units
B)100 units
C)150 units
D)130 units
E)200 units

Question 39

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-If the container size were 15 and there were 10 containers, what would be the new required round-trip time, all else being constant?

A)4 hours
B)5 hours
C)6 hours
D)7 hours
E)8 hours

Question 40

Lady Bug Machineries uses a lean production assembly line to make its generators. In one assembly area, the demand is 200 parts per 8-hour day. It uses a container that holds 10 parts. It typically takes about 5 hours to round-trip a container from one work center to the next and back again. They also desire to hold a 20% safety stock of this part in the system.

-If the container size is 15 and there are 10 containers, what will be the demand per hour, all else being constant?

A)240 parts
B)100 parts
C)25 parts
D)30 parts
E)200 parts

Question 41

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-How many containers should the lean system be using?

A)7
B)17
C)21
D)27
E)30

Question 42

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-Calculate the maximum system inventory for this part.

A)1,350 units
B)850 units
C)1,050 units
D)1,500 units
E)350 units

Question 43

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-If the required safety stock was changed to zero, how many containers should the lean system be using, all else being constant?

A)17
B)24
C)21
D)27
E)30

Question 44

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-Based on the required safety stock of zero and the number of containers computed in Question 43, calculate the maximum inventory for this part.

A)850 units
B)1,350 units
C)1,050 units
D)1,500 units
E)1,200 units

Question 45

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-Based on the required safety stock of zero and the number of containers computed in Question 41, what would be the new required round-trip time, all else being constant?

A)7 hours
B)6.03 hours
C)6.75 hours
D)7.8 hours
E)6 hours

Question 46

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-Based on the required safety stock of zero and the number of containers computed in Question 41, what will be the demand, all else being constant?

A)300 parts per hour
B)275 parts per hour
C)250 parts per hour
D)225 parts per hour
E)200 parts per hour

Question 47

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-If the demand from the original data was changed to 250 parts per hour, how many containers should the lean system be using, all else being constant?

A)34
B)24
C)37
D)27
E)30

Question 48

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-If the demand from the original data was changed to 250 parts per hour and based on the number of containers the lean system should be using, what would be the new required round-trip time, all else being constant?

A)7 hours
B)6.4 hours
C)5.5 hours
D)4.8 hours
E)6 hours

Question 49

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-If the required round-trip time from the original data was changed to 5 hours, how many containers should the lean system be using, all else being constant?

A)32
B)25
C)37
D)27
E)23

Question 50

The Frankenmuth Fasteners Co. was implementing lean throughout their shop floor and needed to determine the number of containers at several of their work centers. In one such work center, the demand was 200 parts per hour, and the containers they used for this part held 50 parts. It normally takes 6 hours for a full container to make a circuit through the work cell and back to its input side, and they desired to carry 12% safety stock in the system.

-If the required round-trip time were 5 hours and there were 23 containers, what would be the safety stock for the lean system?

A)5%
B)3.5%
C)10%
D)12%
E)15%