Question 1

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

Accepted Answer

Mass production typically involves producing large quantities of standardized products, often using assembly lines, which may require more workers, inventory, and space to manage the scale of production efficiently.

Question 2

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

Accepted Answer

The individual generally credited with the development of lean production is Taiichi Ohno, a Japanese engineer and businessman who worked for Toyota.

Question 3

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

Accepted Answer

Small-lot production means producing goods in smaller quantities, which requires less space and lower capital investment compared to mass production. This can be advantageous for small businesses or for testing new products before committing to large-scale production.

Question 4

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

Accepted Answer

General purpose machines can be easily reconfigured to perform different tasks, making them a flexible resource that can be used in lean production.

Question 5

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

Accepted Answer

Small-lot production reduces lead time and can also improve quality by allowing for quicker identification and resolution of defects.

Question 6

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

Accepted Answer

Kanbans are used in pull production systems, where products are produced based on customer demand, rather than being pushed through the production process. The use of kanbans helps to regulate the flow of materials and avoid overproduction.

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.

Accepted Answer

The answer of Waiting for parts to arrive or for...

Question 8

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

Accepted Answer

Takt time is the pace at which production needs to occur in order to meet customer demand. It is calculated by dividing the available production time by the customer demand. It does not necessarily mean maximum output, as the goal is to match production with demand in order to minimize waste and maximize efficiency.

Question 9

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

Accepted Answer

The answer of Manufacturing cells are comprised of groups of...

Question 10

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

Accepted Answer

Kaizen is a Japanese term that translates to "continuous improvement" and refers to the philosophy of constantly improving processes and practices to increase efficiency and reduce waste. While it may involve methods to prevent defects, "fool proofing" specifically is not the definition of Kaizen.

Question 11

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

Accepted Answer

The number of kanbans required is calculated using the formula: Number of Kanbans = (Demand during Lead Time + Safety Stock) / Container Size. Hence, demand and lead time information are necessary for calculating the number of kanbans needed to maintain control in a pull system.

Question 12

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

Accepted Answer

With small-lot production, inventory levels are kept low to avoid waste and excess storage costs. This means that the output of one process is closely tied to the input of the next process, creating a stronger interdependence between processes. Any disruption or delay in one process can cause a ripple effect throughout the production line, making it more challenging to maintain production schedules and meet customer demands.

Question 13

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

Accepted Answer

Producing items before they are needed can lead to excess inventory, which is considered waste in lean production. The goal of lean production is to have a continuous flow of goods with minimal waste and inventory.

Question 14

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

Accepted Answer

Taiichi Ohno, one of the fathers of the Toyota Production System, observed that American supermarkets pull items through the system based on what is needed to satisfy demand, which is one of the key principles of just-in-time manufacturing.

Question 15

Kanbans were derived from the two-bin inventory system.

Accepted Answer

Kanbans were developed by Taiichi Ohno at Toyota and were based on the two-bin inventory system, which had been used in supermarkets in the US.

Question 16

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

Accepted Answer

In lean production, waste is defined as anything that does not add value to the product. This is a key principle of lean thinking, and the elimination of waste is a central goal of lean production systems. Examples of waste include overproduction, waiting, defects, unnecessary processing, excess inventory, unnecessary motions or movement, and unused employee creativity or skills. By identifying and eliminating these forms of waste, lean production systems can improve efficiency and productivity, reduce costs and lead times, and improve overall product quality and customer satisfaction.

Question 17

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

Accepted Answer

The statement is true.

Question 18

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

Accepted Answer

Pull production requires a fundamental shift in the way production is planned and executed, as it relies on demand to drive production rather than forecasts or schedules. It may require significant changes to processes and systems.

Question 19

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

Accepted Answer

Push systems are based on predetermined schedules, often created by computer programs, which establish what products or parts need to be produced and when.

Question 20

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

Accepted Answer

A kanban square is a marked area that indicates the maximum amount of inventory that should be held in a particular location. It is often used in lean manufacturing as a visual signal to indicate when more production is needed, and to help reduce waste and improve efficiency.

Quiz 23: Lean Systems