Question 1

Calculate the inventory container size required given the following: Demand rate = 10 parts per hour, Safety stock required = 15%
Number of containers = 14, Time to cycle through entire system = 6 hours
A)2 parts
B)3 parts
C)4 parts
D)5 parts

Accepted Answer

The answer of Calculate the inventory container size required given...

Question 2

Which of the following best describes the five S's?
A)These were originally Japanese words relating to industrial housekeeping
B)Five ways to reduce inventories on the shop floor
C)These are five different kinds of manufacturing layouts
D)Refer to methods for reducing setup times

Accepted Answer

The five S's refer to a methodology that originated in Japan, focusing on workplace organization and standardization to improve efficiency, safety, and cleanliness. The terms are Seiri, Seiton, Seiso, Seiketsu, and Shitsuke, which translate to Sort, Set in order, Shine, Standardize, and Sustain, respectively.

Question 3

Successful supply chains evolve through stages; the internally focused stage is characterized by all of the following EXCEPT:
A)Functional silos
B)Top-down management
C)Long-term planning
D)Internal measures used to monitor performance

Accepted Answer

The internally focused stage is characterized by functional silos, top-down management, and internal measures used to monitor performance. However, it typically does not involve long-term planning, as the focus is on optimizing internal operations rather than coordinating with external partners.

Question 4

The Quick Response program, developed in the 1980's, was an offshoot of the following supply chain concept:
A)Efficient Consumer Response
B)Six Sigma
C)Just-in-Time
D)Cross Docking

Accepted Answer

The Quick Response program was developed as an offshoot of the Just-in-Time (JIT) supply chain concept, which focuses on reducing inventory levels and increasing efficiency by receiving goods only as they are needed in the production process.

Question 5

All of the following are included in the seven wastes EXCEPT:
A)Overproducing
B)Overprocessing
C)Overspending
D)Waiting

Accepted Answer

The seven wastes in Lean methodology are overproduction, waiting, transportation, processing, motion, inventory, and defects. Overspending is not considered as a waste in Lean methodology.

Question 6

Successful supply chains evolve through stages; the following stage is characterized by an emphasis on cost reduction:
A)Internally Focused
B)Functional Integration
C)Internal Integration
D)External Integration

Accepted Answer

The answer of Successful supply chains evolve through stages; the...

Question 7

Lean production systems are sometimes referred to as pull systems because demand from customers activates the production actions of the manufacturing facilities.In order for this demand to be communicated to everyone in the supply chain/manufacturing facility a signal must be passed from downstream processing centers to the upstream processing centers.This system of relaying signals is referred to as a:
A)Kanban System
B)Semaphore System
C)Keiretsu Network
D)TQM Network

Accepted Answer

The system of relaying signals from downstream to upstream processing centers in a lean production system is known as the Kanban system. This system ensures that each processing center produces only what is needed by the next downstream center, thereby minimizing waste and reducing inventory costs. Semaphore systems are used for communication with flags or lights, Keiretsu networks are a type of business structure in Japan, and TQM networks are quality management systems.

Question 8

Which of the following is NOT consistent with the lean philosophy?
A)Cross-training employees to increase processing flexibility
B)Developing a culture of continuous improvement within the organization
C)Increasing batch size to take advantage of economies of scale
D)Positioning WIP inventories near each processing center

Accepted Answer

Increasing batch size goes against the lean philosophy, which aims to minimize inventory and eliminate waste. By increasing batch size, inventory is increased, and the potential for waste is also increased. The lean philosophy instead advocates for small batch sizes to allow for quicker response times, reduced inventory, and increased flexibility.

Question 9

Which of the following is NOT one of the Seven Wastes?
A)Excess inventories
B)Environmental waste
C)Waiting time
D)Scrap and rework

Accepted Answer

The Seven Wastes are commonly referred to as TIMWOODS, which stands for Transport, Inventory, Motion, Waiting, Over-production, Over-processing, Defects, and the eighth waste is often added as unused employee skills. Environmental waste is not part of the Seven Wastes.

Question 10

Modern supply chains simultaneously pursue the goals of high-quality, fast response, and low cost because customers nowadays want both high levels of quality and responsiveness.A key manufacturing philosophy that emphasizes waste elimination and minimizing inventories to expose problems is:
A)Just-in-time
B)Quick Response
C)Efficient Consumer Response
D)Total Quality Management

Accepted Answer

Just-in-time is a key manufacturing philosophy that emphasizes waste elimination, minimizing inventories, and exposing problems. This approach enables manufacturers to achieve high levels of quality, fast response, and low cost simultaneously.

Question 11

While the philosophy of Six Sigma means different things to different people and is practiced differently in different companies, according to the textbook, two of the more important and agreed-upon elements of Six Sigma are:
A)Minimizing inventories and increasing material flow
B)Focusing on the customer and workforce involvement
C)Rewarding employees and keeping defect rates below 2%
D)Minimizing inventories and keeping defect rates below 1%

Accepted Answer

Focusing on the customer is a key element of Six Sigma as it emphasizes meeting the customer's needs and exceeding their expectations, while workforce involvement is important to ensure that everyone is engaged in the improvement process and working towards the same goal. While minimizing inventories and keeping defect rates low are also important aspects of Six Sigma, they are not the most agreed-upon or widely recognized elements. Rewarding employees is also not necessarily a core component, as it is more focused on incentivizing and recognizing individual performance rather than improving the overall process.

Question 12

The following is a term that refers to error- or mistake proofing:
A)Kaizen
B)Muda
C)Lean layouts
D)Poka-yoke

Accepted Answer

Poka-yoke is a Japanese term that refers to mistake-proofing or error-proofing. It involves implementing mechanisms or techniques to prevent or detect errors before they cause defects. This approach helps to improve quality, reduce waste, and increase efficiency.

Question 13

The element of lean involving firms working with buyers and customers with the mutual goal of eliminating waste, improving speed, and improving quality is referred to as:
A)Waste reduction
B)Lean supply chain relationships
C)Lean layouts
D)Continuous improvement

Accepted Answer

Lean supply chain relationships involve collaboration between firms and their customers with the goal of eliminating waste, improving speed, and improving quality. This involves communication and cooperation to streamline processes, reduce lead times, and improve product offerings.

Question 14

Which of the following layouts is primarily designed to process parts, components, or jobs requiring the same or similar processing steps, saving duplication of equipment and labor:
A)Work centers
B)Production kanban
C)Work-in-process
D)Manufacturing Cells

Accepted Answer

Manufacturing cells are designed to group together similar processing steps in order to minimize duplication of equipment and labor. This layout is also known as a cellular manufacturing layout. Work centers, production kanban, and work-in-process layouts do not necessarily prioritize grouping similar processing steps together.

Question 15

Lean production emphasizes all of the following EXCEPT:
A)Continuous improvement
B)Reduction of waste
C)Synchronization of material flows
D)Large batch sizes

Accepted Answer

Lean production aims to minimize waste and maximize value by reducing batch sizes and synchronizing material flows. Large batch sizes lead to excess inventory, overproduction, and longer lead times, which goes against the principles of lean production. Therefore, option D is the correct answer as it contradicts the fundamental principles of lean production.

Question 16

Which of the following are among the most important elements of the lean production philosophy?
A)Quality inspections and a standardized product line
B)Fully automated assembly lines and a large supplier base
C)Large inventories and quality inspections
D)Waste reduction and continuous improvement

Accepted Answer

Lean production philosophy's most important elements are waste reduction and continuous improvement. Quality inspections and standardized products (A) may be important but are not the most important elements. Fully automated assembly lines (B) and a large supplier base may not be relevant to lean production philosophy. Large inventories and quality inspections (C) are actually opposite to the principles of lean production philosophy.

Question 17

Japanese manufacturing firms sometimes create cooperative coalitions with their suppliers in order to provide the suppliers with a certain degree of financial support.What are these cooperative coalitions called?
A)Jidoka Networks
B)Keiretsu Networks
C)Kanban Networks
D)Kaizen Networks

Accepted Answer

Cooperative coalitions created by Japanese manufacturing firms with their suppliers are called Keiretsu Networks.

Question 18

Lean thinking is a philosophy incorporating tools which seek to optimize:
A)Human Resources
B)Assets
C)Productivity
D)All of these

Accepted Answer

Lean thinking seeks to optimize all of these - human resources, assets, and productivity. It focuses on eliminating waste, improving flow, and continuously improving processes to create maximum value for customers while minimizing any unnecessary costs or effort.

Question 19

Which company probably played the largest role in the development of the Toyota Production System?
A)General Motors
B)Ford
C)Chrysler
D)Boeing

Accepted Answer

Ford's production system, particularly their use of the assembly line, heavily influenced the development of the Toyota Production System. Toyota leaders visited Ford's plants in Detroit in the 1950s to observe their production methods and adapted many of their ideas to create their own system.

Question 20

Efficient Consumer Response was initially developed in the 1990's for the following industry:
A)Fashion
B)Grocery
C)Small Electronics
D)Automobile

Accepted Answer

Efficient Consumer Response (ECR) was initially developed in the 1990s for the grocery industry. It is a collaborative effort between retailers and manufacturers to optimize the supply chain, reduce costs, and improve customer satisfaction.

Quiz 8: Process Management: Lean and Six Sigma in the Supply Chain

Calculate the inventory container size required given the following: Demand rate = 10 parts per hour, Safety stock required = 15% Number of containers = 14, Time to cycle through entire system = 6 hours

Which of the following best describes the five S's?

Successful supply chains evolve through stages; the internally focused stage is characterized by all of the following EXCEPT:

The Quick Response program, developed in the 1980's, was an offshoot of the following supply chain concept:

All of the following are included in the seven wastes EXCEPT:

Successful supply chains evolve through stages; the following stage is characterized by an emphasis on cost reduction:

Which of the following is NOT consistent with the lean philosophy?

Which of the following is NOT one of the Seven Wastes?

Modern supply chains simultaneously pursue the goals of high-quality, fast response, and low cost because customers nowadays want both high levels of quality and responsiveness.A key manufacturing philosophy that emphasizes waste elimination and minimizing inventories to expose problems is:

While the philosophy of Six Sigma means different things to different people and is practiced differently in different companies, according to the textbook, two of the more important and agreed-upon elements of Six Sigma are:

The following is a term that refers to error- or mistake proofing:

The element of lean involving firms working with buyers and customers with the mutual goal of eliminating waste, improving speed, and improving quality is referred to as:

Which of the following layouts is primarily designed to process parts, components, or jobs requiring the same or similar processing steps, saving duplication of equipment and labor:

Lean production emphasizes all of the following EXCEPT:

Which of the following are among the most important elements of the lean production philosophy?

Japanese manufacturing firms sometimes create cooperative coalitions with their suppliers in order to provide the suppliers with a certain degree of financial support.What are these cooperative coalitions called?

Lean thinking is a philosophy incorporating tools which seek to optimize:

Which company probably played the largest role in the development of the Toyota Production System?

Efficient Consumer Response was initially developed in the 1990's for the following industry: