Deck 17: Lean Operating Systems

Question 1

Large batches often provide economies of scale and helps firms match inventory to market demand.

Answer 1

False

Question 2

Firms use the "5S" principles to create a clean and organized work environment.

Answer 2

True

Question 3

The 5Ss focus on improving waste generated by inefficient transportation.

Answer 3

False

Question 4

JIT systems are based on the concept associated with pull systems rather than push systems.

Question 5

Lean operating systems seek to apply the principles of continuous flow to the production of discrete parts by reducing batch size, ideally to a size of one.

Question 6

In a push system, finished goods inventory is produced in advance of customer demand using a forecast of sales.

Question 7

In lean thinking, waste need not be classified as simply material waste such as scrap and defective parts.

Question 8

According to the Toyota Motor Company, waiting time is a necessary evil in production and is not classified as waste.

Question 9

The number of Kanban cards is directly proportional to the amount of work-in-process inventory.

Question 10

In a JIT system, the computer inventory data is the interface and control point between customers and supply cycles.

Question 11

Synchronization of the value chain is a lean approach to increasing speed and response.

Question 12

Lean enterprise refers to approaches that focus on the elimination of defects and errors throughout the value chain.

Question 13

Lean Six Sigma is simply the union of lean approaches with quality improvement techniques, each of which has been used independently in other applications.

Question 14

Lean principles are of primary benefit to manufacturers and provide little value to service organizations.

Question 15

The goal of total productive maintenance is to minimize the costs associated with routine maintenance activities.

Question 16

To accomplish single piece flow, a manufacturer needs the ability to change between products quickly and inexpensively.

Question 17

Single minute exchange of dies (SMED) frees up capacity for other productive uses.

Question 18

A goal of total productive maintenance is to have zero accidents in the entire life cycle of the operating system.

Question 19

A clean and organized work area is an important principle of lean thinking.

Question 20

Kanban is a Japanese term for elimination of waste.

Question 21

Total Productive Maintenance (TPM) strives to relieve machine operators of routine maintenance so that they can focus entirely on being productive.

Question 22

When producing a broad goods or service mix with diverse requirements on common equipment, the ideal strategy is to run large batches.

Question 23

Production Kanbans trigger the movement of parts.

Question 24

According to the Toyota Motor Company, which of the following is not one of the seven major waste categories?

A)Overproduction
B)Transportation
C)Motion
D)Single-piece flow

Question 25

A withdrawal Kanban

A)Authorizes production
B)Authorizes suppliers to produce
C)Authorizes the transfer of an empty container
D)Authorizes shipping to customers

Question 26

In the 5Ss, items identified as unnecessary and thus removed from a workplace would be included with which S?

A)Sort
B)Synchronize
C)Shine
D)Standardize

Question 27

Long lead-times and higher work-in-process is most closely related to which of Toyota's "Seven Major Waste Categories"?

A)Overproduction
B)Single-piece flow
C)Waiting time
D)Transportation

Question 28

Which of the following is least related to a push system?

A)Maximum customer responsiveness
B)Predefined schedule
C)Finished goods inventory
D)Based on forecast

Question 29

Which of the following is not a basic principle of a lean operating system?

A)Elimination of waste
B)Batching
C)Increased speed and response
D)Improved quality

Question 30

Which of the following is not one of the 5Ss?

A)Synchronize
B)Standardize
C)Shine
D)Sustain

Question 31

The number of Kanban cards is dependent on all of the following except

A)Average daily demand rate
B)Setup time
C)Part waiting time
D)Safety stock

Question 32

Which one of the following statements is true concerning Lean Six Sigma?

A)Lean principles focus on advanced statistical methods.
B)Lean principles have been developed over a sixty year plus period of time.
C)Lean principles include the 5Ss framework and practices.
D)Six Sigma and lean principles are not related-they are separate bodies of knowledge.

Question 33

Quick setup or changeover of tooling and fixtures is associated with ____.

A)Visual controls
B)Single minute exchange of dies
C)5Ss
D)Six Sigma

Question 34

Which of the following is least related to a pull system?

A)Building inventory
B)Final assembly schedule
C)Real time information
D)Sales rate

Question 35

Total productive maintenance (TPM) seeks to do all of the following except ____.

A)Maximize equipment effectiveness
B)Create worker ownership
C)Foster continuous improvement efforts
D)Enable multiple products in small batches to be run on the same equipment

Question 36

Quality at the source requires

A)Starting with a plan
B)Having reliable suppliers
C)Doing it right the first time
D)Having a good design

Question 37

Six Sigma addresses visible problems in processes; lean production is more concerned with less visible problems.

Question 38

Toyota classified waste into seven major categories. Those categories include all of the following except

A)Motion
B)Ordering
C)Inventory
D)Waiting

Question 39

Total Production Maintenance (TPM)

A)Puts total responsibility on maintenance workers
B)Puts total responsibility on equipment operators
C)Eliminates all down time
D)Employees preserve and protect their equipment

Question 40

Lean production is focused on efficiency by reducing waste and improving process flow, while Six Sigma is focused on effectiveness by reducing errors and defects.

Question 41

Ford Motor Company has decided to switch to a pull system of manufacturing and distribution for its vehicles. Which one of the following is most likely to occur?

A)Inventory levels will increase.
B)Component parts and subassemblies will be replenished only when needed.
C)Dealer parking lot space will need to be increased.
D)Finished goods inventory will decrease, but raw materials and work-in-process inventories will increase.

Question 42

Which of the following "lean" ideas is false?

A)Activities not adding value are a waste.
B)Accidents are a form of waste.
C)A pull system produces waste.
D)Overproduction is a form of waste.

Question 43

Explain the 5Ss.

Question 44

Compare and contrast a push system vs. a pull system.

Question 45

ABC Manufacturing uses a Kanban system for a component. The daily demand is 800 units. Each container has a combined waiting and processing time of 0.34 days. If the container size is 50 and efficiency (safety) factor is 9 percent, how many Kanban card sets should be authorized (round up)?

A)5 sets
B)6 sets
C)7 sets
D)8 sets

Question 46

Southwest Airlines illustrates the application of "lean principles" when it

A)reduces airplane turnaround time at airport gates.
B)assigns airplane seats.
C)serves all passengers in-flight dinners.
D)requires a change of ticket fee for missing a scheduled flight.

Question 47

Principles of lean operating systems include all of the following except

A)Eliminate waste
B)Reduce workforce
C)Increase speed and response
D)Reduce cost

Question 48

Define a Kanban. Describe how it helps execute a pull system.

Question 49

Which one of the following statements is true?

A)The heijunka system is a system of boxes much like in a mailroom set of boxes attached to a wall used to smooth production outputs.
B)Producing goods early is a principle of lean.
C)A university publication printed with 100% post-consumer recycled fiber is an example of total productive maintenance practice.
D)Preventive maintenance is not a part of lean principles and practices.

Question 50

Which one of the following statements is true?

A)Postponement is the process of delaying orders from suppliers because it is very difficult to order from geographically dispersed businesses.
B)General Motors supply chain is a good example of a push system.
C)Dell Computers supply chain is a good example of push system.
D)Flexibility and responsive service are top priorities compared to low cost in an efficient supply chain.

Question 51

A manufacturer of automobile engines is designing a new Kanban system for engine #321. The demand for #321 is 75/day and they are built in groups of 8. The total process and wait time is 3 days. The manager wants an alpha ( $\alpha$ ) of 2 or 200%. How many Kanbans are required?

Question 52

Explain the purpose of visual controls and give examples.

Question 53

Explain the concept of Single Minute Exchange of Die (SMED).

Question 54

In a Kanban system, the numerator of the formula K = [d(p + w)(1 + $\alpha$ )]/C is analogous to

A)demand during the lead time only in a fixed quantity inventory system.
B)safety stock only in a fixed period inventory system.
C)the order up-to-level (M) in a fixed period inventory system.
D)the reorder point (r) in a fixed quantity inventory system.

Question 55

Contrast batching with single-piece flow.

Question 56

Discuss the seven major categories of waste as defined by Toyota.

Question 57

Define lean enterprise and the four principles of lean operating systems.

Question 58

Discuss the differences between lean production and Six Sigma.

Question 59

How does Total Productive Maintenance (TPM) affect lean operating systems?

Question 60

Hinge Manufacturing Company employs a Kanban system for a component part. The daily demand is 900 hinges. Each container has a wait time of 0.05/day, and a processing time of 0.37 days. The Container size is 60 hinges and the safety factor ( $\alpha$ ) is 10%.
a.How many Kanban card sets should be authorized?
b.What is the maximum inventory of this hinge in the system?

Question 61

A company is using Kanban containers. There are two adjacent work centers, a downstream (using) and an upstream (producing) one. The using work center has a production rate of 200 parts per day and each container holds 20 parts. It takes .5 days for a container to make the entire cycle from the time it leaves the upstream center until it is returned, filled with production, and leaves again. The manager wants a safety factor ( $\alpha$ ) of 20%. The company is interested in reducing the number of containers.
a.What is the number of containers currently in use?
b.If the number of parts a container holds is increased to 24 parts, how many containers are needed?
c.If the company wants the number of containers (holding 20 parts each) to be 5, what must the safety factor become?

Question 62

A manufacturing company is using a two-container Kanban system between a downstream (using) and an upstream (producing) work center. Each container holds 25 parts. The using work center can handle 100 parts per day. The average elapsed time for the entire cycle is currently .40 days. The company is concerned about the efficiency of the operation.
a.What is the safety factor for the current operation?
b.What is the maximum authorized inventory for this part?
c.If the number of containers is reduced to one, how many parts must it hold?
d.If the efficiency is changed to .10 and the number of parts per container is increased to 44, how many containers will be needed?

Question 63

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 .25 days. The company is concerned with the safety factor for the operation and the size of the containers.
a.What is the efficiency rating of the current operation?
b.If the company decides to use only one container, how many parts must it hold?
c.If the safety factor is changed to .12 and there are still 2 containers, how many parts must each container now hold?