Deck 8: Lean Systems

Question 1

Push systems are often used in firms with highly repetitive processes and well defined work flows of standardized items.

Answer 1

False

Question 2

The just-in-time (JIT)philosophy is the belief that cutting inventory and removing non-value-added activities in operations can eliminate waste.

Answer 2

True

Question 3

Kaizen is the Japanese term for continuous improvement.

Answer 3

True

Question 4

In manufacturing systems,one way to achieve continuous improvement can be to maintain low inventories,and periodically cut safety stocks almost to zero.

Question 5

The goal of single-digit setup is to have a setup completed in fewer than 10 hours.

Question 6

In service systems,a common approach used to stress the system and identify problems is to reduce the number of employees doing an activity until the process begins to slow or come to a halt.

Question 7

In a lean system,wait times can be caused to some extent by long production runs.

Question 8

In lean systems,work-in-process inventory is a direct result of overproduction and waiting.

Question 9

In a lean system,large inventories are not considered a type of waste,because they prevent operator wait times.

Question 10

Long production runs,poor material flows,and processes that are not tightly linked to one another can cause over 90% of a product's lead time to be spent waiting.

Question 11

Using expensive,high precision equipment,even when simpler machines would suffice,is encouraged when lean systems are implemented,because this is the only way high quality manufacturing can be achieved.

Question 12

In lean systems,the need for single-digit setups is driven by the desire for small lot sizes.

Question 13

If infrequent,large shipments of purchased items are arranged with suppliers,large inventory savings for these items can be realized.

Question 14

JIT II refers to a form of supplier partnership that places a supplier representative,who is empowered to plan and schedule the replenishment of materials from the supplier,in the customer's plant on a full-time basis.

Question 15

Manufacturing an item before it is needed in a lean system is not considered waste,because it helps keep material flowing through the system.

Question 16

While overproduction creates an item before it is needed,the extra time before an item is needed makes it easier to detect defects and reduce their impact on a process.

Question 17

Just-in-time (JIT)systems need close relationships with suppliers.

Question 18

The push method begins the production of items in advance of customer needs.

Question 19

The pull method begins the production of an item in advance of customer needs.

Question 20

In a lean system,excess inventory hides problems on the shop floor,and thus prevents sources of waste from being identified and eliminated.

Question 21

A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 90 seconds.

Question 22

Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method.

Question 23

Heijunka is the leveling of production load by both volume and product mix.

Question 24

Preventive maintenance is typically given very low priority in just-in-time systems.

Question 25

Five S practices can enable workers to visually see everything differently,prioritize tasks,and achieve a greater degree of focus.

Question 26

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

Question 27

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called jidoka.

Question 28

Just-in-time (JIT)systems rely on inspectors to inspect quality into the product.

Question 29

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

Question 30

One tactic of Total Preventive Maintenance (TPM)is to make workers responsible for routine minor maintenance of their own equipment.

Question 31

Productivity tends to increase when components are standardized because each worker performs a standardized task or work method more often each day.

Question 32

Takt time is the cycle time needed to maximize utilization of an organization's workers and equipment.

Question 33

A power cord that can be plugged in only one way is an example of a poka-yoke.

Question 34

The Japanese practice of andon means that production does not begin until a card or bin is empty.

Question 35

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called heijunka.

Question 36

Lean systems are operating systems that maximize the value added of each of its activities by paring unnecessary resources and delays from them.

Question 37

A five S program includes the activities of "simplify" and "system."

Question 38

A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 40 seconds.

Question 39

Takt time is the cycle time needed to match the rate of production to the rate of sales.

Question 40

Five S practices can be applied to both manufacturing and service settings and can include offices,work spaces,tool rooms,and shop floors.

Question 41

A value stream map shows the flows of materials and information and the lines of responsibility and authority.

Question 42

The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints,while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities.

Question 43

While lean systems work very well for manufacturing systems,they cannot be applied to service systems.

Question 44

A one-person cell in which a worker operates several different machines simultaneously to achieve a line flow is called a one-worker,multiple-machines (OWMM)cell.

Question 45

One benefit of a lean system is that it reduces space requirements.

Question 46

Use of value stream mapping requires construction of a current state drawing,a future state drawing,and an implementation plan.

Question 47

Group technology collects similar parts into families and organizes machine tools into separate cells.

Question 48

A Kanban is a card used to control the flow of production in many just-in-time systems.

Question 49

The value stream mapping tool often requires completion of the future state drawing before the current state drawing,to help managers see the future state goals and more easily identify problems with the current state of the process.

Question 50

Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving.

Question 51

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

Question 52

Often in value stream mapping,analysts must rely on process information from shop floor workers rather than direct observation in an effort to quickly develop a work plan and accelerate implementing the improved process.

Question 53

An OWMM arrangement reduces labor requirements but increases inventory.

Question 54

To complete the current state drawing of a process,a map of the current situation is developed,including such items as material and information flows,process times,setup times,batch sizes,scrap rates,and number of people required.

Question 55

After the earthquake and tsunami of 2011,Toyota's suppliers and plants were able to maintain production levels due to their efficiency.

Question 56

The Toyota Production System requires that any process improvements are to be made at the lowest level of the organization.

Question 57

In the Toyota Production System,when a work station needs more material,it is obvious to both the worker and the supplier that material is needed.Further,the amount needed must be understood as well as the delivery time for replenishment.

Question 58

In a Kanban system,materials may be withdrawn without a withdrawal card if the operation requiring the material is about to run out of work.

Question 59

Some Kanban systems are set up without Kanban cards,and use the material containers or open spaces in a work area to withdraw materials.

Question 60

As the average processing time per container of parts increases,fewer containers are needed in a Kanban system.

Question 61

Continuous improvement with lean systems:

A)involves navigating a ship over treacherous rocks.
B)requires periodically increasing lot sizes or workforce levels to uncover problems.
C)entails systematically stressing the system and focusing on problem areas.
D)focuses exclusively on internal operations without addressing relationships with customers and suppliers.

Question 62

One big advantage of lean systems is that they can usually be put in place without any major changes to existing layouts.

Question 63

Lean systems maintain inventory in small lot sizes because small lot sizes:

A)increase pipeline inventory,allowing the organization to buffer against demand uncertainties.
B)increase the quality level of the product.
C)enable schedules to use machine capacities more efficiently.
D)increase manufacturing lead time because of the increase in waiting time.

Question 64

Companies using lean systems generally have:

A)many suppliers to ensure that material shortages never occur.
B)suppliers that are located nearby to decrease delivery lead time.
C)suppliers that are willing to accept short-term contracts.
D)suppliers who are low-cost producers.

Question 65

Mistake-proofing is known by the term:

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

Question 66

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:

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

Question 67

There are many requirements for the successful implementation of the lean system of production.Which one of the following is not such a requirement?

A)uniform assembly schedule
B)short setup time
C)low machine failure and low defects
D)substantial natural resources

Question 68

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,which of the following statements is TRUE?

A)Jobs with excessive motion should be redesigned.
B)Work-in-process inventory is the direct result of underutilization of employees.
C)Manufacturing an item before it is needed helps an organization detect and reduce defects.
D)Product damage and deterioration result from using expensive high precision equipment.

Question 69

What did the production manager say to the pile of scrapped material?

A)"Hello muda."
B)"Hello fadduh."
C)"We need more kanbans."
D)"JIT II Brute?"

Question 70

The lean system concept will not work without the proper environment.Which one of the following characteristics is most common to firms that have successfully implemented a lean system?

A)uniform assembly schedules
B)specialized workforce
C)high rates of machine failures
D)longer setup times

Question 71

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,excessive movement and material handling of product between processes is part of which general waste category?

A)Motion
B)Transportation
C)Inappropriate Processing
D)Underutilization of Employees

Question 72

Lean systems try to:

A)produce a product in anticipation of demand.
B)maximize the value added by of each of its activities.
C)organize production in large lots to minimize the number of setups.
D)reduce the labor content in all processes.

Question 73

Lean systems do not need stable master production schedules.

Question 74

Using customer demand to activate production of an item or service is called:

A)the andon method.
B)the pull method.
C)the jidoka method.
D)the push method.

Question 75

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,manufacturing an item before it is needed is part of which general waste category?

A)Inappropriate Processing
B)Waiting
C)Inventory
D)Overproduction

Question 76

A method in which production of an item begins in advance of customer needs is called:

A)the andon method.
B)the pull method.
C)the jidoka method.
D)the push method.

Question 77

The goal of single-digit setups is to have a setup time:

A)of less than one shift.
B)of less than one hour.
C)of less than 30 minutes.
D)of less than 10 minutes.

Question 78

The just-in-time (JIT)system is a(n):

A)management system of people and procedures to fulfill all delivery deadlines.
B)production system of small-lot manufacturing to reduce work-in-process inventory.
C)materials management system for removing all inventories.
D)integrated system of managing resources,information,and decision processes to eliminate waste.

Question 79

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,using expensive high precision equipment when a simpler machine would suffice is part of which general waste category?

A)Motion
B)Overproduction
C)Inappropriate Processing
D)Defects

Question 80

In the Toyota Production System,services and goods flow to the next available person or machine to maintain smooth,rapid flow.