Deck 16: Lean Systems

Question 1

Kanbans were derived from the two-bin inventory system.

Answer 1

True

Question 2

Taiichi Ohno observed that customers in American supermarkets pull items through the system.

Answer 2

True

Question 3

The time required for a worker to complete one pass through the operations assigned to her is called the operator cycle time.

Answer 3

True

Question 4

Takt time is the pace at which production output is aligned with machine capacity.

Question 5

A kanban square is a marked area designated for holding a set quantity of output.

Question 6

The concept of pull production is easy to implement because it is similar to traditional scheduling procedures.

Question 7

Waiting for parts to arrive or for machines to finish production is considered a form of waste under the principles of mass production.

Question 8

Producing items before they are needed is considered waste under the principles of lean production.

Question 9

In lean production,waste is defined as anything that does not add value to the product.

Question 10

Push systems rely on predetermined production schedules often generated by computerized systems.

Question 11

The individual generally credited with the development of lean production is an American.

Question 12

Mass production means doing more with fewer workers,less inventory,and less space.

Question 13

The number of kanbans needed to maintain control in a pull system can be calculated from demand and lead time information.

Question 14

Advantages of small-lot production include requiring less space and lower capital investment.

Question 15

Kaizen is a Japanese term that means fool proofing to prevent defects.

Question 16

Small-lot production reduces lead time but increases quality problems.

Question 17

Manufacturing cells are comprised of similar machines to process a family of parts.

Question 18

The lower inventory levels associated with small-lot production make processes more dependent on each other.

Question 19

Kanbans are used to maintain the discipline required of a push production system.

Question 20

General purpose machines are an example of flexible resources.

Question 21

One benefit of small lot production is that workers show fewer tendencies to let poor quality pass.

Question 22

Setup time is not a component of the cumulative lead time for a manufactured product.

Question 23

The concept of cellular layouts was developed by a U.S.engineer in the 1920s.

Question 24

The output of a manufacturing cell is changed by adding or removing workers.

Question 25

One component of lead time,setup time,is often the biggest bottle neck.

Question 26

The lower inventory levels resulting from small-lot production hides problems in the production process.

Question 27

A poka-yoke is any foolproof device that prevents defects or injury from occurring.

Question 28

Total productive maintenance combines preventive maintenance with kaizen.

Question 29

Lean concepts cannot be applied to services because services are intangible.

Question 30

Poka-yolk is a Japanese term used to describe the removal of waste in a lean production system.

Question 31

A push system prevents both overproduction and underproduction.

Question 32

In the dual kanban system,a withdrawal kanban authorizes the production of goods.

Question 33

Reducing variability in production through more accurate demand forecasts is one way to maintain uniform production levels.

Question 34

In lean production,a strong relationship exists between setup times and small lots.

Question 35

Flexible resources is a basic element of lean production.

Question 36

Internal setup activities can be performed when a process is running.

Question 37

In a lean production system,kanban systems have been shown to handle large fluctuations in the production requirements on the final assembly line.

Question 38

The authority for a worker to stop the production line when quality problems are encountered is known as poka-yoke.

Question 39

The pull system was developed by Ohno to coordinate production between processes.

Question 40

Mixed-modeling sequencing is used at Toyota to reduce setup times.

Question 41

A workstation must produce 400 units an hour.It takes 24 minutes to receive the necessary material for production from the previous workstation.Output is moved between workstations in containers holding 44 units.If the process uses a safety factor of 10%,then the number of kanbans that should be circulating between this workstation and the previous workstation is

A)2
B)4
C)6
D)8

Question 42

___________ is generally credited with the development of lean production.

A)Frederick Taylor
B)W.Edwards Deming
C)Taiichi Ohno
D)None of the above.

Question 43

Which of the following statements concerning small-lot production is not true?

A)small-lot production requires less space
B)small-lot production requires more capital investment
C)small-lot production simplifies transportation between workstations
D)small-lot production allows processes to be moved closer together

Question 44

In lean production,waste is defined as

A)overproduction.
B)high levels of inventory.
C)unnecessary movement.
D)All the above are waste.

Question 45

How many kanbans should circulate between two workstations if demand is 500 units per hour,lead time is 20 minutes,container sizes are 35,and the company uses a safety factor of 5%?

A)4
B)5
C)12
D)8

Question 46

Lower inventory levels make processes

A)less dependent on each other while keeping bottlenecks hidden.
B)less dependent on each other while revealing bottlenecks more quickly.
C)more dependent on each other while revealing bottlenecks more quickly.
D)more dependent on each other while keeping bottlenecks hidden.

Question 47

All of the following factors pressure companies for quicker response and shorter cycle times except

A)demanding customers.
B)longer product life cycles.
C)globalization.
D)All the above are factors.

Question 48

Which of the following is not a principle for reducing setup times?

A)converting external setup to internal setup
B)converting internal setup to external setup
C)separating internal setup from external setup
D)performing setup activities in parallel

Question 49

The pace at which production should take place to match the rate of customer demand is known as

A)product flow time
B)jidoka time
C)kanban time
D)takt time

Question 50

Which of the following is not a basic element of lean production?

A)flexible resources
B)pull system
C)repetitive production
D)small lot production

Question 51

A workstation's output is 200 bottles of wine per hour.It takes 45 minutes to receive a withdrawal kanban of corks from the previous workstation.The withdrawal kanban is attached to a container holding 30 corks.The process uses a safety factor of 20 percent.What is the number of withdrawal kanbans needed to support the bottling process.

A)4
B)5
C)6
D)3

Question 52

Early adopters of lean production in the U.S.were unsuccessful because they tried to implement lean by slashing inventories and forcing their suppliers to make more frequent deliveries.

Question 53

Which of the following is not a typical component of lead time?

A)processing time
B)maintenance time
C)waiting time
D)setup time

Question 54

Improved scheduling of materials,workers,and machines will most generally affect

A)processing time.
B)move time.
C)waiting time.
D)setup time.

Question 55

Firms that adopt lean production experience reductions in cycle time,inventory cost and employee training costs.

Question 56

A workstation's output is 200 bottles of wine per hour.It takes 30 minutes to receive a withdrawal kanban of corks from the previous workstation.The withdrawal kanban is attached to a container holding 30 corks.The process uses a safety factor of 20 percent.What is the number of withdrawal kanbans needed to support the bottling process?

A)10
B)2
C)8
D)4

Question 57

In a pull system reducing the number of kanbans

A)increases inventory making problems more visible.
B)reduces inventory making problems less visible.
C)reduces inventory making problems more visible.
D)increases inventory making problems less visible.

Question 58

To keep machines running firms can use either breakdown maintenance or preventative maintenance.

Question 59

A workstation must produce 400 units an hour.It takes 24 minutes to receive the necessary material for production from the previous workstation.Output is moved between workstations in containers holding 44 units.If the process uses a safety factor of 10%,then the amount of safety stock on average would be

A)16
B)32
C)8
D)60

Question 60

In a pull production system a card that corresponds to a standard quantity of production is known as a(n)

A)jidoka.
B)andon.
C)kanban.
D)kaizen.

Question 61

Which of the following is not typically a component of lead time?

A)Move time.
B)Breakdown time.
C)Wait time.
D)Setup time.

Question 62

Lean production is difficult to implement when

A)demand is highly variable.
B)product variety is high..
C)there are many unique products.
D)all of the above are true.

Question 63

A ____________ kanban is used to order material in advance of production.

A)material
B)supplier
C)production
D)withdrawal

Question 64

All of the following are benefits expected from implementing lean production except

A)better quality.
B)shorter lead times.
C)reduced capacity.
D)improved sales.

Question 65

Which of the following is not a benefit of lean production?

A)Greater flexibility
B)Increased capacity
C)More customers
D)More product variety

Question 66

What role does the elimination of waste play in lean production?

Question 67

A ___________ is a foolproof device that prevents defects from occurring.

A)kaizen
B)jidoka
C)muda
D)poka-yoke

Question 68

What is a kanban and how is it used in a pull system?

Question 69

Value stream mapping (VSM)is a tool for

A)reducing setup times.
B)improving quality at the source.
C)analyzing process flow.
D)designing manufacturing cells.

Question 70

The authority given to the worker to stop the production line if quality problems are encountered is known as

A)kaizen.
B)jidoka.
C)poka-yoke
D)muda.

Question 71

The concept of allocating extra time to a schedule for planning,problem solving,and maintenance is known as

A)preventative scheduling.
B)preventive maintenance.
C)over capacity maintenance.
D)under capacity scheduling.

Question 72

Analyzing process flow and eliminating waste is referred to as

A)just-in-time.
B)the Toyota Production System.
C)value stream mapping
D)total productive maintenance.

Question 73

What is a manufacturing cell and what is its purpose?

Question 74

Mixed-model sequencing

A)facilitates total productive maintenance.
B)achieves uniform production levels.
C)increases product lead times.
D)reduces worker productivity.

Question 75

What are the benefits of small-lot production?

Question 76

Combining the practice of preventive maintenance with the concepts of total quality is known as

A)total preventive quality.
B)total productive maintenance.
C)quality breakdown maintenance.
D)reliability assurance.

Question 77

How does the pull system differ from the push system?

Question 78

The benefits of lean production include all of the following except reduced

A)inventory.
B)product variety.
C)pace requirements.
D)lead times.

Question 79

______________ setups that can be performed in advance while the machine is running.

A)Internal
B)External
C)Parallel
D)Unnecessary