Question 1

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

Accepted Answer

A value stream map primarily shows the flow of materials and information as they make their way through the process, but it does not explicitly show lines of responsibility and authority.

Question 2

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.

Accepted Answer

The statement accurately describes the difference between the theory of constraints and value stream mapping.

Question 3

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

Accepted Answer

Lean systems can be applied to service systems with some modifications to account for the unique characteristics of service operations.

Question 4

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.

Accepted Answer

The statement accurately describes the concept of a one-worker, multiple-machines cell.

Question 5

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

Accepted Answer

Lean systems are designed to eliminate waste in all forms, including wasted space. By optimizing layouts, minimizing inventory, and improving organization, lean systems can significantly reduce the amount of floor space required for operations. This can lead to lower costs, increased efficiency, and improved overall performance.

Question 6

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

Accepted Answer

Value stream mapping involves creating a visual representation of the current state of a process, identifying areas for improvement and creating a future state drawing to achieve the desired improvements. The implementation plan outlines the steps needed to achieve the future state.

Question 7

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

Accepted Answer

Group technology (GT) is a manufacturing philosophy that seeks to identify and group similar parts into families and organize machine tools into separate cells based on the manufacturing process required for those families. This facilitates efficient production, reduces setup time, and simplifies inventory management.

Question 8

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

Accepted Answer

The statement correctly describes the use of Kanban cards in controlling the production flow in many just-in-time systems.

Question 9

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.

Accepted Answer

Value Stream Mapping typically starts with mapping the current state to understand and visualize the existing processes and identify areas of waste before designing the future state map that outlines improvements and more efficient processes.

Question 10

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.

Accepted Answer

The answer of Toyota sets up all of its operations...

Question 11

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.

Accepted Answer

Assigning one worker to operate several different machines in a line and creating cells for similar product groups are both options for achieving line-flow layouts in a lean system.

Question 12

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.

Accepted Answer

The answer of Often in value stream mapping,analysts must rely...

Question 13

An OWMM arrangement reduces labor requirements but increases inventory.

Accepted Answer

The answer of An OWMM arrangement reduces labor requirements but...

Question 14

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.

Accepted Answer

This statement is true. A map of the current situation in process mapping typically includes information on material and information flows, process times, setup times, batch sizes, scrap rates, and the number of people required to perform each step in the process. This information is used to create a visual representation of the current state of the process, which can be used to identify areas for improvement and optimization.

Question 15

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

Accepted Answer

Toyota's suppliers and plants were severely affected by the earthquake and tsunami of 2011, leading to production disruptions and shortages. It took several months for the company to recover fully, and the disaster had a significant impact on its sales and profits.

Question 16

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

Accepted Answer

The Toyota Production System emphasizes the concept of "kaizen," meaning continuous improvement, and it is expected that any improvement ideas or suggestions come from the workers who are closest to the process. This approach encourages participation and ownership at all levels of the organization.

Question 17

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.

Accepted Answer

In the Toyota Production System, the concept of "pull" is used, where each work station signals to the previous work station that more material is needed, creating a demand-pull system. The amount and delivery time for replenishment are also specified to ensure efficiency in the system.

Question 18

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.

Accepted Answer

In a Kanban system, every withdrawal of materials must be accompanied by a withdrawal card to maintain the discipline of the system and ensure accurate tracking of materials and work in progress.

Question 19

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

Accepted Answer

This is true. Some Kanban systems use visual signals, like colored bins or marked spaces, instead of Kanban cards to indicate material withdrawal.

Question 20

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

Accepted Answer

In a Kanban system, as the average processing time per container of parts increases, more containers are needed to maintain the same level of production flow and meet demand, as each container takes longer to process.

Quiz 8: Lean Systems