Deck 17: Lean Operations and Supply Chains

Question 1

16)Throughput is ______.

A)measured by the ratio of input to output
B)measured by the ratio of waste to output
C)a measure of how an order moves from receipt to delivery
D)a measure of those orders not regulated by the government

Answer 1

C

Question 2

2)Lean concepts were used ______.

A)in 1776 by Adam Smith
B)in the early 1900s by Henry Ford
C)during the industrial revolution
D)to help win World War II

Answer 2

B

Question 3

12)Which of the following terms is correctly paired with its description?

A)mura-waste from the underutilization of workers
B)heijunka-the uneven levels of production resulting from poor management
B)muri-waste from producing products not truly required by society
B)poke yoke-design of product or service such that it is sustainable

Answer 3

A

Question 4

11)A smooth and rapid flow of materials and work can be achieved by ______.

A)eliminating disruptions
B)maintaining a highly structured and rigid system
C)eliminating the carbon footprint
D)beating employees till morale improves

Question 5

17)Which of the following is true with regard to push and pull systems?

A)Push systems are systems in which services or products are produced based on forecasts.
B)In pull systems,the product or service is produced because its production is mandated by a central planning organization.
C)In pull systems,the product or service is regulated by a government agency.
D)In push systems,inventory is completely eliminated.

Question 6

10)Which of the following is not representative of muda?

A)any activity that does not add value
B)any activity that is unproductive
C)waste that occurs from any variation in output
D)any activity that impacts demand elasticity

Question 7

6)The stability and flow of goods in global supply chains can be improved by ______.

A)increasing the carbon footprint
B)minimizing orders for changes in parts,assemblies,specifications,engineering drawings,and documents
C)producing products that are easy to manufacture
D)using only local resources

Question 8

9)Which of the following types of waste is correctly matched with its description?

A)muri-waste and decreased productivity resulting from poor system design
B)mura-tendency to increase the carbon footprint by using resources that are not lean
C)muda-an activity that adds high degree of value
D)poke yoke-product or service design that reduces production costs

Question 9

7)Which of the following is NOT one of the goals of lean health care?

A)improving the quality of care and patient experience
B)simplifying tasks for providers
C)better using resources to treat an expanding patient population without adding more doctors and nurses,beds,or equipment
D)ensuring all patients are treated in an identical manner

Question 10

8)Principles of lean include ______.

A)willingness of managers to impose strict controls on workers
B)elimination of waste and inefficiency
C)avoiding government regulation
D)ensuring that only the most essential products are manufactured

Question 11

20)Deciding whether to use a push or pull system depends upon ______.

A)an organization's philosophy of sustainable operations
B)the type of industry in which the organization competes
C)the extent of regulation enforced by the government
D)the impact of ISO standards on the company's operations

Question 12

3)A just-in-time strategy ______.

A)reduces investment in inventory and reduces space requirements
B)increases investment in inventory but reduces space requirements
C)increases investment in inventory increases space requirements
D)reduces investment in inventory but increases space requirements

Question 13

4)Lean production and just-in-time concepts became important ______.

A)in the mid 1980s,thanks to Motorola
B)in the early 1940s,thanks to Ford
C)in the early 1970s,thanks to Toyota
D)in the mid 1980s,thanks to General Electric

Question 14

14)Incrementalism refers to ______.

A)making radical changes in one big fix
B)making small fixes in a steady stream of improvements
C)being regular in making annual improvements
D)fixing a problem each time it becomes a problem

Question 15

19)With push systems,______.

A)good planning is necessary
B)there is potential for sustainable operations
C)there is no need to maintain inventory
D)government regulation is minimized

Question 16

5)Which of the following is NOT a reason why global sourcing makes it considerably more difficult to implement lean?

A)lower inventory levels
B)longer global supply chains
C)poor accuracy of sales forecasts
D)longer lead times

Question 17

18)The lean philosophy is characterized by ______.

A)pull
B)push
C)assemble-in-anticipation-of-order
D)engineer-in-anticipation-of-order

Question 18

13)What is the correct order of the 5S?

A)sort,sweep,sustain,standardize,straighten
B)sort,straighten,sweep,sustain,standardize
C)straighten,sort,sweep,sustain,standardize
D)sort,straighten,shine,standardize,sustain

Question 19

1)According to lean philosophy,we should eliminate any activity or process ______.

A)that does not add value to the product or service
B)that has a high carbon footprint
C)that is likely to be regulated by the government
D)that does not conform to ISO standards

Question 20

15)Which of the following statements is true with regard to workflow?

A)Workflow is the sequence of connected steps or operations necessary to complete a task.
B)Dependence is the idea that adjustments to one element in the workflow have no implications for other elements.
C)Independence with regard to workflow is the idea that an element in the workflow is not subject to government regulation.
D)Throughput is a measure of speed applied to processes in the service industry.

Question 21

41)Which of the following does not refer to external setups?

A)can be completed outside of the process
B)do not require machinery to be stopped
C)do not require the process to be shut down
D)do not require the retraining of employees

Question 22

31)Which of the following is not a way to achieve a smooth and rapid flow of materials and work?

A)eliminating disruptions
B)keeping the system flexible
C)eliminating waste
D)improving sustainability

Question 23

35)The Japanese term for leveling out the workload or smoothing production is ______.

A)kaizen
B)jidoka
C)poke yoke
D)heijunka

Question 24

28)The use of Lean Six Sigma has ______.

A)increased complacency in the workplace
B)created an organizational climate in which innovation has become instinctive
C)created a hostile work environment
D)eliminated the need for ISO standards

Question 25

33)In a level schedule,materials are pulled through the assembly line at a ______.

A)steady rate
B)fluctuating rate
C)flexible rate
D)inconsistent rate

Question 26

38)Safety stock ______.

A)is the minimal level of inventory that a company seeks to maintain a buffer against the mismatch between forecasted and actual demand
B)is the level of finished products that a company maintains to take advantage of demand in new markets
C)is the level of finished products that a company maintains to ensure it is safe from government inspection
D)is the level of finished products that a company needs to manufacture to ensure the price is protected from increase or decrease

Question 27

24)Which of the following is NOT an attribute of VSM?

A)It a communication tool.
B)It is a business-planning tool.
C)It is a mechanism for managing process change.
D)It is a tool for reducing the carbon footprint.

Question 28

26)Which of the following is NOT one of the elements of total quality management?

A)worker responsibility for quality
B)statistical quality control
C)the use of fail-safe methods
D)reduction of carbon footprint

Question 29

32)Which of the following is not a way to accomplish schedule stability?

A)level schedules
B)frozen windows
C)underuse of capacity
D)uneven production quantities

Question 30

39)A mixed-model production cycle ______.

A)refers to the production of the same mix of products every day in small quantities
B)was pioneered by General Electric
C)is synonymous with Henry Ford's assembly line
D)makes use of the concept of interchangeable parts

Question 31

29)The Japanese word jidoka,or quality at the source,means ______.

A)doing it right the first time
B)terminating employees at the first sign of a problem
C)circumventing government audits of product quality
D)ensuring customer specifications are met on time even at the risk of poor quality

Question 32

22)Value stream mapping (VSM)______.

A)is typically done once an organization has converted to a lean system
B)facilitates identifying sources and causes of waste
C)has the potential to increase the carbon footprint
D)is applied only in push production systems

Question 33

37)Takt______.

A)is the French word for "production level"
B)represents the production cycle
C)represents the marketing cycle
D)represents the audit cycle

Question 34

23)In value stream mapping,we create a visual map of the production process to show ______.

A)value added at each step in the process
B)time required to meet customer needs
C)whether customer specifications have been met
D)the extent of government supervision of this project

Question 35

36)Heijunka is used to ______.

A)reduce production costs
B)level out the workload
C)prevent errors before they occur
D)identify the weakest link in the production chain

Question 36

27)Which of the following is true with regard to Lean and Six Sigma?

A)Lean approaches focus on reducing cost through optimization of the manufacturing process.
B)Six Sigma focuses on the production of those products and services considered to be truly essential to human existence.
C)Lean is relevant to manufacturing,while Six Sigma is relevant to the service industry.
D)Six Sigma refers to the number of deviant personnel involved in the production process.

Question 37

34)Frozen windows are ______.

A)periods during which production levels can be revised
B)specific time periods in which production levels cannot be changed
C)time periods during which there are no quality inspections
D)periods during which employees are not given time off from work

Question 38

25)A VSM is ______.

A)much more narrowly defined in relation to a process flow
B)particularly useful for processes showing a high degree of variation
C)a communication tool
D)a tool for reducing the carbon footprint

Question 39

30)External logistics systems refer to ______.

A)the collection,transportation,and distribution of goods between suppliers and the plant
B)the flow of raw materials between steps in the manufacturing process
C)the dispatch of goods from plant to quality control center
D)the collection,transportation,and distribution of goods between different work stations inside one manufacturing facility

Question 40

40)In a production process,internal setup requires ______.

A)machinery to be stopped
B)new raw materials
C)retraining of employees
D)adherence to price controls

Question 41

46)A prerequisite for setting up a Kanban control system is ______.

A)determining the number of Kanban cards and containers
B)determining the design of the Kanban cards
C)determining whether the Kanban card is going to be used with MTO or ETO
D)determining the color of the Kanban cards

Question 42

54)Features of lean relationships in supply chain management include ______.

A)fewer suppliers
B)increase in number of employees
C)reduced sustainability
D)increase in cash flows

Question 43

55)Information with regard to actual and forecasted customer demand,market opportunities,and responsibilities should be ______.

A)restricted
B)sold
C)transparent
D)subject to government regulation

Question 44

52)Which of the following is NOT one of the principles a service operation should follow to create a lean system?

A)Pinpoint the value of the service offer.
B)Identify the service's value stream.
C)Improve the flow of the service.
D)Design process to meet customer requirements.

Question 45

47)Lot size refers to ______.

A)the number of square feet occupied by the manufacturing facility
B)the predetermined quantity of an item that is purchased from a supplier
C)the location of the parking area within the manufacturing facility
D)the number of units ordered by a given customer

Question 46

50)To achieve large inventory savings,you need ______.

A)an annual replenishment system
B)large shipments of purchased materials and components
C)frequent shipments of purchased materials and components
D)a smaller number of units to be produced and sold

Question 47

43)Kanban______.

A)means level production
B)is a visual signal used to tell workers when it is time to get or make more of something
C)is a visual signal used to tell workers when it is time for lunch
D)is used in the push production system

Question 48

56)In lean logistics,a milk run approach involves ______.

A)making right turns only when driving trucks
B)making multiple drop-offs
C)using full truckloads in transportation
D)avoiding of water transport

Question 49

45)During the backflush process,______.

A)parts that go into each unit of the product are removed from inventory
B)parts that go into each unit of the product are scrapped or refurbished
C)workers make sure of part interchangeability
D)workers confirm that parts are within tolerances specified

Question 50

44)The Kanban system ______.

A)can be used to coordinate suppliers and not just manufacturing plants
B)allows firms to control the flow of resources in a production process by anticipating demand for parts
C)is based on forecasting of demand
D)is based on forecasting of supply

Question 51

59)3PL is associated with ______.

A)improving the efficiency of product flows
B)requiring the manufacturer to focus on its core competencies
C)improving the quality of manufactured products
D)the service industry only

Question 52

60)A supplier park ______,

A)is a solution to the physical separation of suppliers from the manufacturer
B)is particularly appropriate for areas with sparse populations
C)is one way to improve the quality of manufactured products
D)can lead to price increases

Question 53

53)Which of the following is NOT a type of flow common to all supply chains?

A)product and service flows
B)information flows
C)financial flows
D)product returns flows

Question 54

57)Cross-docking ______.

A)can reduce handling and storage costs
B)reduce cycle times
C)increase requirements for intermediate storage
D)reduce sustainability

Question 55

61)Which of the following performance metrics is NOT correctly associated with its description?

A)time metrics-the amount of time to process an order,the transportation time,and similar variables
B)efficiency metrics-evaluate inventory turnover or days of inventory on hand,as well as capacity and capital usage
C)effectiveness metrics-evaluate the percentage of orders delivered on time and customer satisfaction metrics,such as number of customer complaints and percentage of returned items
D)liquidity metrics-employee turnover,absenteeism rates

Question 56

58)VMI______.

A)stands for vendor-managed inventory
B)is a process in which inventory is completely eliminated
C)incorporates the push concept
D)makes it easier to meet quality control requirements

Question 57

49)Which of the following is NOT the result of reducing inventory and its locations?

A)reducing waste
B)streamlining operations
C)simplifying the steps workers need to take
D)reducing sustainability

Question 58

42)Group technology (GT)______.

A)addresses the need for product variety
B)facilitates mass consumption
C)increases the cost per unit of product
D)eliminates the need for quality control

Question 59

48)In determining the correct number of Kanban containers,which of the following is NOT a relevant consideration?

A)processing time for the container
B)waiting time during production
C)transportation time to the shipping area
D)cost of storage of the finished product

Question 60

51)Which of the following is NOT a factor that makes it easier to implement lean in a service delivery system?

A)the extent to which the service delivery system can be standardized
B)the frequency at which services are delivered
C)the consistency of services that are delivered
D)the cost of services that are delivered

Question 61

81)Characteristics of a lean supply chain include ______.

A)greater frequency of quality inspections
B)vendor-managed inventory
C)increased amount of rework
D)increased quantity of scrapped materials

Question 62

65)Which of the following statements is true with regard to JIT in global supply chains?

A)Shipping numerous small quantities of products is less cost-effective over long distances.
B)Communication is not as important as it is replaced by Kanban.
C)JIT can increase the number of suppliers.
D)JIT can decrease the quality of goods supplied.

Question 63

78)Lean operations ______.

A)have the goal of eliminating waste of any kind
B)impact manufacturing but not service organizations
C)produce only short-term benefits
D)are required for ISO certification

Question 64

79)Which of the following is NOT one of the tenets of the philosophy of lean?

A)promoting respect for people
B)eliminating waste and inefficiency
C)commitment to the 5S model
D)terminating those employees who are below average in productivity

Question 65

74)Which of the following is NOT true with regard to lean and sustainability?

A)Lean implementation supports a company's desire to act in an ethically responsible manner.
B)Lean systems foster waste elimination.
C)Lean implementation can cause discomfort and stress among some employees.
D)Lean systems encourage continuous improvement.

Question 66

62)Metrics often used to monitor the performance of lean supply chains include ______.

A)days of inventory on hand
B)return on investment
C)employee turnover
D)absenteeism rates

Question 67

64)Making global supply chains lean ______.

A)is difficult because it requires coordination to establish the rapid flow of goods and information
B)is easy because annual deliveries required for JIT inventory management are easy to achieve
C)is inexpensive because there is no need for safety stock
C)reduces the need for quality control

Question 68

70)Which of the following is a lean initiative that is consistent with sustainability practices?

A)increase in use of raw materials
B)avoiding overproduction
C)increased frequency of quality inspections
D)employing more quality control personnel

Question 69

71)Which of the following is a lean initiative that is consistent with sustainability practices?

A)increase in use of raw materials
B)reducing transportation requirements
C)increased frequency of quality inspections
D)employing more quality control personnel

Question 70

73)Which of the following is NOT consistent with lean practices?

A)reduced waiting
B)reducing transportation
C)minimizing overproduction
D)excess motion

Question 71

69)Environmentally sustainable practices ______.

A)are a natural extension of lean
B)are inconsistent with lean practices
C)increase the challenges in applying lean principles
D)are a substitute for lean practices

Question 72

76)Possible ways by which a company can overcome the adverse impact of lean on employees include ______.

A)guaranteeing the jobs of those employees who are dedicated and willing to go through additional training to support lean implementation
B)assuring employees that their jobs will not be affected even if they are completely incompetent
C)threatening employees with government-approved sanctions
D)advising employees who remain that their salary will be doubled

Question 73

67)Which of the following is a consequence of having a global supply chain?

A)reduction in communication problems
B)increase in speed of delivery of supplies
C)better quality control because of easy supervision
D)longer lead times

Question 74

80)Characteristics of a lean supply chain include ______.

A)full collaboration of all supply chain partners
B)reduction in the transparency of information pertaining to supply chain operations
C)increase in inspection of raw materials obtained
D)increase in number of employees

Question 75

77)Lean operations ______.

A)include just-in-time (JIT)practices
B)is a philosophy of radical improvement
C)benefit all employees in an organization
D)are easy to implement in a global supply chain

Question 76

63)CTP______.

A)stands for a cost-time-profile map
B)tracks whether value is added at each step in the production process
C)tracks the quality of production at each step in the production process
D)tracks the quantity of production at each step in the production process

Question 77

68)Different activities in a global supply chain ______.

A)are of equal importance in the value they add
B)may need to be traded-one against the other-to help managers prioritize
C)can be avoided by doing all activities in-house
D)none of these

Question 78

72)Which of the following is a lean initiative that is consistent with sustainability practices?

A)increase in waiting time
B)less excess inventory
C)increased frequency of quality inspections
D)employing more quality control personnel

Question 79

66)Which of the following is not a consequence of incorporating lean in a global supply chain?

A)JIT and low inventories
B)reduction of defects
C)reduction of engineering change orders
D)following design-for-manufacturing principles

Question 80

75)Implementing lean ______.

A)may lead to increase in payroll costs
B)may cause stress and discomfort for some employees
C)may lead to usage of additional materials and resources
D)may reduce production quality levels