Deck 10: Process Improvement: Lean

Question 1

Which of the following is/are (a)primary tenet(s)in the Japanese work systems?

A)Waste is minimized
B)Continually improving process and systems
C)Six sigma implementation
D)Both A and B
E)None of the above

Answer 1

Both A and B

Question 2

The goal of single minute exchange of die is to reduce setup times to less than 10 minutes.

Answer 2

True

Question 3

Which of the following is not one of the seven categories of waste or muda?

A)Waiting
B)Inventory
C)Underproduction
D)Defects

Answer 3

Underproduction

Question 4

In traditional approaches to production,preventive maintenance is also common.

Question 5

Which of the following is not a direct benefit of lean?

A)Cost savings
B)Uncovering problems
C)Improved financial investments
D)Revenue increases

Question 6

A patient diagnosis is an example of what type of activity?

A)Value-added
B)Non-value-added but necessary
C)Non-value-added and not necessary
D)Necessary and value-neutral

Question 7

Mixed-model assembly requires optimized production technology (OPT)for sequencing.

Question 8

The following are characteristics of Lean when contrasted with traditional systems,except:

A)Priorities are a limited market and few options
B)Capacity is flexible and moderately utilized
C)Suppliers are many,competitive,deliver to central receiving area and have independent forecasts
D)Quality is at the source,continuous and with statistical process controls

Question 9

Japanese production approaches such as JIT could not be applied in the United States because companies do not show much respect and loyalty to their employees.

Question 10

The step in the 5S approach in which standardized procedures for maintaining an orderly work environment are developed and implemented is:

A)Sort
B)Straighten (Set in order)
C)Scrub (Shine)
D)Systemize

Question 11

The step in the 5s approach in which the other four steps are made a habit is:

A)Sort
B)Straighten (Set in order)
C)Scrub (Shine)
D)Systemize

Question 12

A diagram where the physical flows of the parts are mapped onto the shop floor is referred to as muda.

Question 13

The step in the 5S approach in which unnecessary steps are eliminated is called:

A)Sort
B)Straighten (Set in order)
C)Scrub (Shine)
D)Systemize

Question 14

The __________ offers a systematic way to view and analyze process flows.

A)Optimized production technology (OPT)
B)Pull system
C)Theory of constraints
D)Progression theory

Question 15

Which of the following is false about Optimized Production Technology (OPT)?

A)Bottleneck workstations in the shop must be identified
B)Bottleneck workstations must be scheduled for full utilization
C)Capacities are to be balanced throughout the shop
D)Non-bottleneck workstations must be scheduled to keep bottlenecks busy so they never wait for work

Question 16

A value stream map:

A)Can only be used in manufacturing facilities
B)May also be used for service providers
C)Shows the flow of materials and information with suppliers shown on the left of the diagram and customers on the right
D)Both B and C

Question 17

Takt time is calculated as

A)Demand volume divided by customer required volume
B)Customer required volume divided by available work time
C)Available work time divided by customer required volume
D)Available work time divided by demand volume
E)Any of the above can be used

Question 18

Pursuing perfection in lean organizations involves which of the following tools?

A)5S,the visual factory and kaizen
B)Six Sigma,Project management and continuous improvement
C)Poka yoke and total productive maintenance
D)Both A and C

Question 19

The following are characteristics of continuous flow manufacturing (CFM),except:

A)Work should flow through the process without interruption
B)Work is organized based on the similarity of the work performed (a functional organization)
C)Work flows one unit at a time,based on the customer's demand rate
D)The phrase "don't let the parts touch the floor" exemplify CFM

Question 20

The goal of this approach is to mistake-proof work activities in a way that prevents errors from being committed in the first place:

A)Kaizen blitz
B)Poka Yoke
C)5S
D)Six sigma
E)OPT

Question 21

If your processing plant were put under a tight deadline,using the Theory of Constraints,would it be more efficient to use a transfer batch smaller or larger than the current process batch in order to reduce batch flow times? Explain your answer.

Question 22

The idea behind the Kanban system is to authorize materials for production only if there is a need for them.

Question 23

The Japanese work systems tend to be based on three primary tenants.What are they?

Question 24

Saving time at non-bottleneck workstations increases total output by an average of five minutes per part per operation.

Question 25

Describe the Japanese culture that lead to the development of lean.

Question 26

Waste can be defined as those activities that consume resources but from the customer's perspective create no value.From this perspective,waste is often classified into seven categories.Briefly describe these.

Question 27

The goal of Kaizen blitz is to mistake-proof work activities in a way that prevents errors from being committed in the first place.

Question 28

Key aspects of the theory of constraints include identifying the bottlenecks in the process and balancing the work flows in the system.

Question 29

A measure of overall ________ ________ is calculated as the product of equipment availability,equipment efficiency,and the rate of quality output.

Question 30

How are suppliers viewed under lean?

Question 31

Describe the lean layout.

Question 32

In general,there are five primary types of benefits of lean.What are they?

Question 33

Briefly describe the ten guidelines of the theory of constraints.

Question 34

Provide an example of how a bottleneck in a manufacturing plant can affect the output of the entire system.

Question 35

The idea of authorizing materials for production only if there is a need for them originated the materials management system known as ________.

Question 36

It is often clear the advantages of a JIT (just in time)system for the manufacturing industry.On the other hand,what are some of the advantages of JIT for the service industry?

Question 37

Lean enterprises rely on the push system,whereby company supply drives the production process.

Question 38

What is the Japanese view of inventories?

Question 39

What is the goal of poka yoke?