Deck 5: Process Improvement: Reducing Waste Through Lean

Question 1

Japanese production approaches such as JIT could not be applied in the United States because companies do not show much respect and loyalty to their employees.

Answer 1

False

Question 2

The step in the 5s approach in which unnecessary steps are eliminated is called:

A)Sort
B)Straighten (Set in order)
C)Scrub (Shine)
D)Systemize

Answer 2

A

Question 3

The step in the 5s approach in which the other four steps are made a habit is:

A)Sort
B)Standardize (Sustain)
C)Scrub (Shine)
D)Systemize

Answer 3

B

Question 4

The goal of this approach is to mistake-proof work activities in a way that prevents errors from being committed in the first place:

A)Kaizen blitz
B)Poka Yoke
C)5s
D)Six sigma

Question 5

The step in the 5S approach in which standardized procedures for maintaining an orderly work environment are developed and implemented is:

A)Sort
B)Straighten (Set in order)
C)Scrub (Shine)
D)Systemize

Question 6

Which of the following is NOT one of the seven categories of waste or muda?

A)Waiting
B)Inventory
C)Underproduction
D)Defects

Question 7

A value stream map:

A)Can only be used in manufacturing facilities
B)May also be used for service providers
C)Shows the flow of materials and information with suppliers shown on the left of the diagram and customers on the right
D)Both B and C

Question 8

In traditional approaches to production,preventive maintenance is also common.

Question 9

The lean tool to reduce setup times is SMED; this acronym stands for

A)Sample minute exchange of dry
B)Single minute exchange of die
C)Simple minute exchange of die
D)Simple minute exchange of dry

Question 10

Which of the following is FALSE about Optimized Production Technology (OPT)?

A)Bottleneck workstations in the shop must be identified
B)Bottleneck workstations must be scheduled for full utilization
C)Capacities are to be balanced throughout the shop
D)Non-bottleneck workstations must be scheduled to keep bottlenecks busy so they never wait for work

Question 11

Takt time is calculated as

A)Demand volume divided by customer required volume
B)Customer required volume divided by available work time
C)Available work time divided by customer required volume
D)Available work time divided by demand volume

Question 12

Pursuing perfection in lean organizations involves which of the following tools?

A)5S,the visual factory and kaizen
B)Six Sigma,Project management and continuous improvement
C)Poka yoke and total productive maintenance
D)Both A and C

Question 13

A diagram where the physical flows of the parts are mapped onto the shop floor is referred to as muda.

Question 14

The following are characteristics of continuous flow manufacturing (CFM),EXCEPT:

A)Work should flow through the process without interruption
B)Work is organized based on the similarity of the work performed (a functional organization)
C)Work flows one unit at a time,based on the customer's demand rate
D)The phrase "don't let the parts touch the floor" exemplify CFM

Question 15

The __________ offers a systematic way to view and analyze process flows.

A)Optimized Production Technology (OPT)
B)Pull system
C)Theory of constraints
D)Progression theory

Question 16

Which of the following is/are (a)primary tenet(s)in the Japanese work systems?

A)Waste is minimized
B)Continually improving process and systems
C)Six sigma implementation
D)Both A and B

Question 17

Which of the following is NOT a direct benefit of lean?

A)Cost savings
B)Uncovering problems
C)Improved financial investments
D)Revenue increases

Question 18

The following are characteristics of Lean when contrasted with traditional systems,EXCEPT:

A)Priorities are a limited market and few options
B)Capacity is flexible and moderately utilized
C)Suppliers are many,competitive,deliver to central receiving area and have independent forecasts
D)Quality is at the source,continuous and with statistical process controls

Question 19

The goal of single minute exchange of die is to reduce setup times to less than 10 minutes.

Question 20

A patient diagnosis is an example of what type of activity?

A)Value-added
B)Non-value-added but necessary
C)Non-value-added and not necessary
D)Necessary and value-neutral

Question 21

The goal of Kaizen blitz is to mistake-proof work activities in a way that prevents errors from being committed in the first place.

Question 22

A measure of overall ________ ________ is calculated as the product of equipment availability,equipment efficiency,and the rate of quality output.

Question 23

The idea of authorizing materials for production only if there is a need for them originated the materials management system known as ________.

Question 24

The idea behind the Kanban system is to authorize materials for production only if there is a need for them.

Question 25

Lean enterprises rely on the push system,whereby company supply drives the production process.

Question 26

Key aspects of the theory of constraints include identifying the bottlenecks in the process and balancing the work flows in the system.

Question 27

Repairing a machine when it breaks down,as opposed to conducting maintenance before it is expected to fail,or at regular intervals is also known as ______ maintenance.

Question 28

Saving time at non-bottleneck workstations increases total output by an average of five minutes per part per operation.

Question 29

Mixed-model assembly requires optimized production technology (OPT)for sequencing.