Deck 23: Lean Systems

Question 1

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

Answer 1

False

Question 2

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

Answer 2

False

Question 3

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

Answer 3

True

Question 4

General purpose machines are an example of flexible resources in lean production.

Question 5

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

Question 6

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

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

Takt time is the pace at which production output is maximum.

Question 9

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

Question 10

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

Question 11

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

Question 12

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

Question 13

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

Question 14

Taiichi Ohno observed that customers in American supermarkets pull items through the system based on what is needed to satisfy demand.

Question 15

Kanbans were derived from the two-bin inventory system.

Question 16

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

Question 17

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

Question 18

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

Question 19

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

Question 20

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

Question 21

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

Question 22

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

Question 23

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

Question 24

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

Question 25

Total productive maintenance combines preventive maintenance with kaizen.

Question 26

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

Question 27

Lean concepts cannot be applied to services.

Question 28

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

Question 29

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

Question 30

Flexible resources is one of the basic elements of lean production.

Question 31

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

Question 32

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

Question 33

In a lean production system,kanban systems have been shown to handle large fluctuations in production requirements on the final assembly line with no problem.

Question 34

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

Question 35

Mixed-modeling sequencing is used at Toyota to create uniform production levels.

Question 36

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

Question 37

Unlike a pull system,a push system prevents both overproduction and underproduction.

Question 38

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

Question 39

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

Question 40

In lean production,a strong relationship exists between setup times and lot size.

Question 41

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 42

___________ is generally credited with the development of lean production.

A)Frederick Taylor
B)W.Edwards Deming
C)Taiichi Ohno
D)None of the answer choices is correct.

Question 43

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

Question 44

Firms that adopt lean production experience reductions in employee training costs.

Question 45

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 46

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 47

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 48

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

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

Question 49

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 50

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 51

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 52

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 53

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 54

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 of the answer choices are correct.

Question 55

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 56

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

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

Question 57

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 58

In lean production,waste is defined as

A)overproduction.
B)high levels of inventory.
C)unnecessary movement.
D)All of the answer choices are correct.

Question 59

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 60

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 61

Which of the following are characteristic of lean applications U.S.soil?

A)plants are larger
B)deliveries from suppliers are less frequent
C)Kanbans are kept very simple.
D)All of these answer choices are correct.

Question 62

American workers implementing lean prefer

A)the slow pace of continuous improvement.
B)the fast pace of kaizen blitzes.
C)to never participate.
D)to disrupt the process.

Question 63

The most prevalent applications of lean include all the following except

A)retailing.
B)health care.
C)food services.
D)banking.

Question 64

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 these answer choices are correct.

Question 65

Mixed-model sequencing

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

Question 66

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 67

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 68

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

A)inventory.
B)product variety.
C)costs.
D)lead times.

Question 69

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 70

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 71

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 72

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

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

Question 73

Lean can have serious deficiencies when applied to companies that have

A)high variability in demand.
B)large variety of low-volume products.
C)custom engineered products.
D)All of these answer choices are correct.

Question 74

Lean and Six Sigma are

A)natural partners for process improvement.
B)natural partners for supply chain management.
C)poor partners for process improvement.
D)poor partners for supply chain improvement.

Question 75

Successful companies use lean to

A)finely tune an operating system.
B)overhaul an operating system.
C)replace an operating system.
D)None of these answer choices is correct.

Question 76

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 77

Which of the following is not a recommendation by the EPA concerning integrating lean and environmental initiatives?

A)Use lean process tools to identify areas of environmental waste.
B)Incorporate environmental,safety,and health data into value mapping.
C)Add environmental waste to the seven wastes of lean.
D)Use lean concepts to eliminate all environment waste.

Question 78

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 79

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 80

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

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