Deck 12: Lean Enterprise

Question 1

Since inventory is required to conduct business,inventory is never considered as a waste of resources in a lean production system.

Answer 1

False

Question 2

A JIT inventory management system uses extra inventory to balance production needs.

Answer 2

False

Question 3

Perfection is a goal of a lean production system.

Answer 3

True

Question 4

A pull production system is based on forecasts to determine production amounts.

Question 5

The main objective of a lean production system is to reduce variation.

Question 6

Production activities that are wasteful and do not add value to the product are considered as Muri.

Question 7

Lean production concepts are only applicable to manufacturing,not services.

Question 8

The objective of "quality at the source" is to minimize inspection costs.

Question 9

The time spent on setting up a machine is considered as waste in a lean production system.

Question 10

A pull production process is appropriate to use instead of a push system when demand is relatively stable.

Question 11

Lean production systems use large batch sizes to minimize setup times.

Question 12

Takt time is defined as the minimum cycle time allowed for producing a product in order to meet demand.

Question 13

In a lean production system,anything that does not add value is considered waste.

Question 14

Lean producers generally use price as the primary criterion for supplier selection.

Question 15

A key aspect to a lean production system is for a worker to specialize in one task and do it well.

Question 16

A push production system focuses on maximizing the use of production capacity.

Question 17

The concept of lean production comes from the Ford Production System.

Question 18

Group technology is used to identify commonalities among components.

Question 19

An organized work environment is the key to a lean manufacturing system.

Question 20

Using standardized components will reduce manufacturing efficiencies.

Question 21

Which of the following is not considered a source of waste?

A)Overproduction
B)Setup Time
C)Poor Quality
D)Labor
E)Movement

Question 22

Lean concepts can be applied to manufacturing,services,and nonprofit organizations.

Question 23

A production system that uses customer demand as the primary driver for production planning is what?

A)Push system
B)Pull system
C)Lean system
D)Quality system
E)Forecasting system

Question 24

Lean Six Sigma has six "laws" to make the process successful.

Question 25

What is the preferred batch size for a lean production system?

A)As large as possible
B)As small as possible
C)Batch size of one
D)A one day supply
E)Batch size is not related to lean

Question 26

Lean systems depend on visual cues and have little opportunity for technology to be utilized.

Question 27

The ratio of total demand to net time available to work is takt time.

Question 28

What is the card that is used to control production in a lean production system called?

A)Kanban
B)JIT
C)SMED
D)Pull card
E)Takt

Question 29

A lean enterprise defines waste very narrowly.

Question 30

Which five-S term means to separate needed material from unneeded items?

A)Sort
B)Straighten
C)Shine
D)Standardize
E)Sustain

Question 31

Which of the following is not descriptive of a producer who might use a push production system?

A)Highly repetitive processes
B)Long lead times
C)Products with common processes
D)Customers who will not wait for products
E)Products with accurate forecasts

Question 32

Lean production is based on a push system of process flow.

Question 33

The law of velocity suggests that the speed of any process is directly related to the amount of work or things in process.

Question 34

Which company is generally credited with developing the concept of lean production?

A)Toyota
B)IBM
C)Honda
D)Dell
E)Kellogs

Question 35

Concurrent engineering utilizes multiple production units,including suppliers,to improve processes.

Question 36

Preventive maintenance is an important component to a lean system and allows lower levels of buffer inventory between workstations.

Question 37

What term is closest to the meaning for Kaizen?

A)Cycle time
B)Automation
C)Quality
D)Continuous improvement
E)Waste

Question 38

Which of the following is not one of the "five-S" principles to create a more organized work environment?

A)Sort
B)Shine
C)Standardize
D)Sustain
E)Supply

Question 39

Lean "thinking" originated in Japan.

Question 40

When might a pull production system not be the most appropriate solution?

A)Products with long setup times
B)Products with seasonality
C)Products with wide variation in demand
D)Products with stable demand
E)Products that are difficult to forecast

Question 41

What are the five laws of the Lean Six Sigma approach?

Question 42

Locating production facilities close to distribution facilities is a way to minimize waste resulting from what?

A)Waiting
B)Transportation
C)Movement
D)Inventory
E)Processing time

Question 43

Identify and describe the three broad groups of waste according to the Toyota Production System.

Question 44

Which of the following is not one of the five different "laws" used in the Lean Six Sigma approach?

A)The law of the market
B)The law of flexibility
C)The law of focus
D)The law of velocity
E)The law of quality

Question 45

Which of the following is not a tool used during the implementation of a lean production system?

A)RFID
B)Five S
C)Preventive maintenance
D)Visual controls
E)Value stream mapping

Question 46

Which of the following is not descriptive of supplies in a lean environment?

A)Frequent shipment
B)Lowest production cost
C)Short lead time
D)Arrival on schedule
E)High quality

Question 47

A production system that uses customer demand to signal production planning is what type of system?

A)Pull
B)Push
C)Efficient
D)Customer driven
E)Kanban

Question 48

Lean systems place a priority on all the following activities except

A)Match production to demand
B)Reducing setup times
C)Adding inspection stations
D)Reduce processing times
E)Minimize movement

Question 49

Identify five of the components of a lean production system.

Question 50

Standardization can reduce what type of waste?

A)Muda
B)Mura
C)Muri
D)Many
E)Mexia

Question 51

In an assembly line following a lean philosophy,what would a worker do who found a quality problem?

A)Report the problem at the end of the shift
B)Report who made the mistake
C)Stop the line and fix the problem
D)Fix the problem personally at the end of the shift
E)Let the inspector fix the problem

Question 52

What are the five S principles to create a more organized work space?

Question 53

What are the five core components of a lean production system?

Question 54

Making the right amount of inventory available at the right time is an objective of what inventory management approach?

A)JIT
B)SMED
C)Kanban
D)Muda
E)Jidoka

Question 55

Which of the following is not an important aspect of a lean production system?

A)Kaizen
B)Close supplier relationships
C)Multifunctional workers
D)JIT
E)Six Sigma quality levels

Question 56

Lean principles include all the following except that

A)Value is defined from the customers' point of view
B)Actions that do not add value should be eliminated
C)Continuous improvement
D)Products should be pushed to the customer
E)Value creation should be organized in a tight and integrated sequence

Question 57

What is the opposite of "muda"?

A)Waste
B)Value
C)Cost
D)Inflate
E)Streamline

Question 58

Additional inventory creates all the following problems except

A)Ability to meet demand
B)Extra handling
C)Production lead time
D)Extra storage
E)Decreases reaction times

Question 59

The most economical batch size is proportional to the square root of

A)Batch time
B)Cycle time
C)Delay time
D)Setup time
E)SMED

Question 60

Which of the following is not true about lean production systems?

A)Minimizing supplier variability is a goal
B)Minimizing customer variability is a goal
C)It focuses on waste elimination
D)Lean production is only applicable to manufacturing
E)Minimizing internal variability

Question 61

A machine makes a floor lamp model and a desk lamp model.The setup time for either lamp is 10 minutes.A floor lamp can be produced in 3 minutes and a desk lamp can be produced in 2 minutes.125 floor lamps are needed per day and 100 desk lamps are needed per day.Calculate how much setup times should be reduced if the batch sizes are reduced to 1?

Question 62

Calculate the takt time if a company has demand for 2100 items a week.8.0 hours of work time is available per day and the company works 6 days a week.

Question 63

A widget maker needs 400 style A widgets a day.The remainder of the time is used to make other style widgets.What is the most economical batch size if the setup time is 30 minutes and the processing time is 1.5 minutes?

Question 64

Calculate the takt time if a company has demand for 300 items a day.7.5 hours of work time are available per day and the company works 5 days a week.

Question 65

A widget maker needs 400 style A widgets a day.The remainder of the time is used to make other style widgets.Calculate the setup time if the batch size used is100 units and the processing time is 1.5 minutes.

Question 66

A widget maker needs 400 style A widgets a day.The remainder of the time is used to make other style widgets.Calculate the setup time if the batch size used is 1 unit and the processing time is 1.5 minutes.

Question 67

What is "lean thinking" in relation to a production system?

Question 68

Calculate the takt time if a company has demand for 1500 items a day,7.0 hours of work time are available per shift,and the company works 2 shifts a day.

Question 69

What is the objective of quality at the source?

Question 70

Describe a kanban system.

Question 71

Describe the difference in a pull and a push production system.

Question 72

A machine makes a floor lamp model and a desk lamp model.The setup time for either lamp is 10 minutes.A floor lamp can be produced in 3 minutes and a desk lamp can be produced in 2 minutes.125 floor lamps are needed per day and 100 desk lamps are needed per day.Calculate how much setup times should be reduced if the batch sizes are reduced to 20?

Question 73

Identify five wastes commonly found in a production system.

Question 74

A machine makes a floor lamp model and a desk lamp model.The setup time for either lamp is 10 minutes.A floor lamp can be produced in 3 minutes and a desk lamp can be produced in 2 minutes.125 floor lamps are needed per day and 100 desk lamps are needed per day.What is the most economical production batch size for each lamp?

Question 75

If a process has a takt time of 2 minutes and has 15 hours available per day spread over two shifts.What is the demand the company can satisfy per day?