Deck 7: Lean Thinking and Lean Systems

Question 1

The ideal setup time for a lean system is:

A)5 minutes
B)The time it takes the line to get ready
C)0 minutes
D)1 hour

Answer 1

C

Question 2

If a manufacturer has daily requirements for products A,B and C of 360,100,and 300,respectively,then the daily schedule will call for the following amounts of each product to be produced per cycle:

A)| (36)A (10)B (30)C |
B)| (18)A (5)B (15)C |
C)| (72)A (20)B (60)C |
D)| (18)A (10)B (30)C |

Answer 2

B

Question 3

How many cycles are required each day for the above daily requirements?

A)16
B)10
C)20
D)5

Answer 3

C

Question 4

Which of the following is not an element of lean?

A)Small-lot production
B)Modularized master schedule
C)Multifunction workers
D)Kanban pull system
E)Perfect or nearly perfect quality

Question 5

The time it takes a container to complete an entire circuit consists of:

A)Move time,time used,and wait time
B)Wait time,run time,setup time,and idle time
C)Fill time,wait time,move time,time used,and time to be returned to be filled again
D)None of the above

Question 6

According to the lean philosophy,it is required to maintain a stable master production schedule to reduce the work-in-process inventories.

Question 7

For production control,lean pull systems are best suited for:

A)Repetitive manufacturing
B)Job shop production
C)Semi-repetitive batch manufacturing
D)None of the above

Question 8

Reduction of setup time is accomplished by separating internal and external setups and:

A)Reducing inventory
B)Implementing a Kanban system
C)Converting internal setup time to external setup time
D)Reducing lot sizes

Question 9

The principal objective of a lean system is:

A)Worker participation
B)Reduction of inventory
C)Reduction of setup times
D)Improve the ROI of the firm

Question 10

External setups refer to actions that require stoppage of the production process.

Question 11

Value stream maps are similar to flowcharts and are used for identifying the waste and non-value-added steps in the current process.

Question 12

External setup time refers to:

A)The time it takes workers to set up a machine during scheduled maintenance
B)The time to complete setup activities that do not require that the machine be stopped
C)The time it takes equipment vendors to set up the machine
D)None of the above

Question 13

Given the following information pertaining to item AX143,determine the appropriate number of kanban cards that should be used to support production. Demand rate = 500 units/week
Lead time = 2 weeks
Safety Stock = 30 percent
Size of Container = 5 units

A)260 units
B)200 units
C)150 units
D)250 units

Question 14

Why is production leveled in a lean system?

A)To create a uniform workload on all work centers
B)To allow for production of safety stock
C)To signal the need for more parts
D)To increase the time for scheduled maintenance

Question 15

The ideal lot size for a lean system is:

A)Infinite
B)One
C)The capacity of the machine
D)Variable according to the production requirements
E)None of the above

Question 16

If it takes 100 minutes to complete a circuit,demand at the next work center is 5 parts per minute,and a container will hold 20 parts,how many containers are required?

A)25
B)5
C)40
D)20

Question 17

A kanban card is used to signal that:

A)The next work center is stopped
B)A materials handler has run out of parts
C)A machine has broken down
D)Parts are needed by the subsequent work center
E)A machine is ready for preventive maintenance

Question 18

If a work center has no empty containers,the workers at the work center will do which of the following?

A)Continue to produce as much inventory as they can
B)Produce enough inventory to meet the following day's demand
C)Produce enough inventory to satisfy the master production schedule
D)Stop production

Question 19

Which of the following is not required for a lean system?

A)Flexible workforce
B)A Type II MRP system
C)A stable master schedule
D)Kanban pull system

Question 20

With regards to suppliers,lean systems typically require:

A)Delivery of large lots at frequent intervals
B)Buyer inspection of goods and materials
C)Multiple sources from which to purchase
D)Long-term relationships and commitments
E)The lowest price possible

Question 21

What are the eight forms of waste?

Question 22

When kanban is used,only the final assembly department will receive a schedule from the dispatching office.

Question 23

Kaizen events typically take between 1 to 2 months.

Question 24

With lean thinking,a company's operations layout should evolve to a cellular manufacturing layout.

Question 25

Lean is an example of a pull system while lean thinking is an example of a push system.

Question 26

One-touch setups could require as long as 9 minutes to perform.

Question 27

The key to reducing inventory is reducing lead-time.

Question 28

Poka-yoke is another term for stabilizing the master schedule.

Question 29

What are the five essential elements of lean thinking? In your own words,provide a road map for implementing lean thinking in a manufacturing or service operations.

Question 30

The Japanese term for waste is "gemba."

Question 31

A Kanban card system finds good utility in a job shop type of production process in regulating the workflow through the shop.

Question 32

"Gemba" refers to data collection using the company's information system.

Question 33

Takt time is calculated by taking demand over some period divided by the available time for production during that period.