Deck 14: Jit and Lean Operations

Question 1

Ideally, preventive maintenance will be performed before a breakdown or failure.

Answer 1

True

Question 2

In the area of maintenance, the Pareto phenomenon is reflected in the fact that, regardless of problem classification, all equipment will justify about the same expense.

Answer 2

False

Question 3

The four building blocks of lean operations are: product design, process design, personnel/organizational elements, and manufacturing planning and control.

Answer 3

True

Question 4

A functioning MRP system is required prior to adopting lean planning and control systems.

Question 5

In the lean philosophy, producinglarge lot sizes reduces waste.

Question 6

Breakdown maintenance includes activities such as equipment inspection and adjustment.

Question 7

Fast and simple are two common threads that run through the four building blocks of lean operations.

Question 8

Breakdown maintenance is best performed on a regularly scheduled basis.

Question 9

In the broadest sense, preventive maintenance extends back to the installation stage of equipment and facilities.

Question 10

The goal of maintenance is to minimize cost.

Question 11

Although inventories are maintained, the goal of lean operations is to minimize safety stock.

Question 12

Pareto analysis (using the 80/20 rule)is one method of determining when preventive maintenance activities should be performed.

Question 13

In a lean environment, anything not essential to the product or process is viewed as waste.

Question 14

The small lot-sizing policy works well in a situation where both holding costs and setup costs are high.

Question 15

Degree of technology is a factor affecting the decision of how much preventive maintenance is desirable.

Question 16

Value stream mapping is a technique focused on finding new ways of adding value for critical stakeholders such as customers.

Question 17

The goal of maintenance is to maintain the productive system in good working order while minimizing or eliminating the cost of preventive maintenance.

Question 18

One basis for scheduling preventive maintenance is passage of time.

Question 19

Quality and highly capable production systems are requirements for the successful implementation of lean operations.

Question 20

The ultimate goal of lean operations is a system characterized by the smooth, rapid flow of materials.

Question 21

Preventive maintenance is additional maintenance done immediately after a breakdown has occurred to help prevent any further breakdowns.

Question 22

A goal of lean operations is to produce output using fewer resources than traditional planning systems.

Question 23

"Autonomation" indicates that the firm is attempting to reduce its dependence on automated equipment.

Question 24

Engineering changes should not be made in the six-month period following the introduction of a new product.

Question 25

A fundamental tenet of the lean philosophy is that workers are paid based on seniority.

Question 26

A basic requirement for operating with low inventories in lean systems is that major system problems must already have been solved and new problems will be solved as they appear.

Question 27

Limited WIP lowers inventory carrying costs but reduces flexibility.

Question 28

Setup time and its associated cost can often be reduced by the use of group technology.

Question 29

Lean systems often use layouts that are based on multiple manufacturing cells.

Question 30

In lean operations, a responsibility of the worker is to check the quality of their work.

Question 31

The use of small lot sizes in lean operations is in conflict with the EOQ approach since setup costs tend to be significantly higher than holding costs.

Question 32

Preventive maintenance will eliminate the need to carry supplies of spare parts.

Question 33

In lean operations, when work is completed at one work center, it is important to immediately move the completed work to the next work center to minimize idle time.

Question 34

A real advantage of the lean philosophy is the reduction of coordination effort required with supply chain partners.

Question 35

In the lean approach, inventories are reduced gradually, instead of eliminating inventories as rapidly as possible.

Question 36

In a pull system, the accumulation of excessive inventory in front of a workstation is avoided even if there are problems such as equipment failure at that workstation which prevent it from completing its work.

Question 37

One problem with lean operations is that they can lead to much stress on workers due to their increased responsibility for process and quality improvement.

Question 38

In the lean philosophy, the larger the lot size, the easier it is to schedule.

Question 39

A benefit of small lot sizes in lean systems is that each product is produced less frequently.

Question 40

The lean philosophy recognizes that some work-in-process inventories are a necessary investment to allow for smooth work flow.

Question 41

Kanban is the Japanese term for autonomation.

Question 42

Lean systems typically require that suppliers be able to provide large lots at periodic intervals.

Question 43

The optimum amount of preventive maintenance occurs when the production system is kept in good working order and

A)total breakdown costs are at a minimum.
B)total preventive maintenance costs are at a minimum.
C)each maintenance component cost is at a minimum.
D)total maintenance costs are at a maximum.
E)total maintenance costs are at a minimum.

Question 44

Increased setup times generally require increased work-in-process inventories.

Question 45

Suppose that for a particular piece of machinery, the frequency distribution of monthly breakdowns is as follows:

The cost of a breakdown is $2,000, and the cost of a preventive maintenance program is $2,000 per month. If the preventive maintenance program is adopted, the probability of a machine breakdown is negligible. How much better off per month would the firm be if it adopted preventive maintenance?

A)$100 worse off
B)$200 worse off
C)$100 better off
D)$200 better off
E)$2,000 better off

Question 46

A benefit of the lean philosophy is the flexibility to respond quickly to changing customer product preferences.

Question 47

Lean purchasing requires frequent contract bidding by multiple sources to ensure the buyer of competitive prices.

Question 48

Maintenance activities are often organized into the following two groups

A)breakdown maintenance and preventive maintenance.
B)breakdown maintenance and predictive maintenance.
C)preventive maintenance and predictive maintenance.
D)equipment maintenance and breakdown maintenance.
E)equipment maintenance and buildings maintenance.

Question 49

Lean operations reduce the number of suppliers the organizationworks with by limiting contacts to two tiers of suppliers.

Question 50

One major difference between the use of kanban and MRP in scheduling theitems to beproduced or ordered is that kanban is primarily a manual system while MRP uses computers.

Question 51

A requirement of lean systems is that lead times are increased, allowing more time for processing.

Question 52

___________ is most closely associated with breakdown maintenance.

A)Equipment adjustment
B)Equipment cleaning
C)Equipment inspection
D)Repair of broken parts
E)Replacement of worn parts

Question 53

The type of maintenance which is periodic in nature is

A)breakdown maintenance.
B)predictive maintenance.
C)preventive maintenance.
D)corrective maintenance.
E)all of the choices.

Question 54

Breakdown maintenance is _____________; preventive maintenance is _________.

A)reactive; proactive
B)proactive; reactive
C)expensive; inexpensive
D)inexpensive; expensive
E)easy; hard

Question 55

Suppose that for a particular piece of machinery, the frequency distribution of monthly breakdowns is as follows:

The cost of a breakdown is $2,000, and the cost of a preventive maintenance program is $2,000 per month. If the preventive maintenance program is adopted, the probability of a machine breakdown is negligible. How much better off per month would the firm be if it adopted preventive maintenance?

A)$100 worse off
B)$200 worse off
C)$100 better off
D)$200 better off
E)$2,000 better off

Question 56

Potential costs of equipment breakdown do not include

A)loss of output.
B)cost of idle workers.
C)damage to other equipment.
D)replacement of worn parts.
E)injuries.

Question 57

Suppose that the average time before breakdown is normally distributed with a mean of 2.5 weeks and a standard deviation of .4 weeks. If breakdowns cost an average of $1,200 and preventive maintenance costs $800, what is the optimal maintenance interval?

A)Every .67 weeks
B)Every .33 weeks
C)Every 2.67 weeks
D)Every 3.25 weeks
E)Every 3.12 weeks

Question 58

Kanban focuses on specific part numbers; CONWIP does not.

Question 59

The goal of maintenance is to maintain the productive system in good working order while minimizing

A)total preventive maintenance costs.
B)total breakdown maintenance costs.
C)total maintenance costs.
D)the difference between preventive and breakdown costs.
E)the ratio of breakdown to preventive maintenance costs.

Question 60

Factors affecting the decision of how much preventive maintenance is desirable typically include all of the following except

A)age of equipment.
B)type of product.
C)degree of technology.
D)type of production process.
E)condition of equipment.

Question 61

Which of the following is not a reason for having machines and equipment in good operating condition?

A)lower the production processing
B)no added service or production costs
C)maintain high quality
D)avoid missed delivery dates
E)avoid production or service disruptions

Question 62

Which of the following is not a major approach used to deal with breakdowns?

A)backup equipment
B)cost of repairs
C)spare parts
D)operators
E)repair technicians

Question 63

The average time before breakdown of a machine is normally distributed and has a mean of 18 weeks and a standard deviation of three weeks. If breakdown cost averages $2,000 and preventive maintenance costs $1,400, what is the optimal preventive maintenance interval?

A)16.4 weeks
B)14.6 weeks
C)16.9 weeks
D)19.6 weeks
E)21.3 weeks

Question 64

Attempting to determine when preventive maintenance activities should be performed is called

A)breakdown maintenance.
B)forecastive maintenance.
C)preventive maintenance.
D)predictive maintenance.
E)corrective maintenance.

Question 65

The average time before breakdown of a machine is normally distributed and has a mean of nine weeks and a standard deviation of 1.5 weeks. If breakdown cost averages $1,500 and preventive maintenance costs $500, what is the optimal preventive maintenance interval?

A)3.8 weeks
B)8.4 weeks
C)9.6 weeks
D)6.9 weeks
E)7.2 weeks

Question 66

Which of the following is the primary consideration with regard to preventive maintenance?

A)what technology to use
B)how varied the maintenance will be
C)how often the maintenance will occur
D)which products it will be provided to
E)who will do it

Question 67

Breakdown programs often are prioritized such that some equipment gets a lot of attention and other equipment gets very little. This typically reflects the fact that breakdowns are consistent with

A)Pareto phenomena.
B)production interruptions.
C)supply disturbances.
D)cross-trained workers.
E)lean operations.

Question 68

_____ is known as being a reactive approach to maintenance.

A)Breakdown maintenance
B)Preventative maintenance
C)Predictive maintenance
D)Corrective maintenance
E)Condition-based maintenance

Question 69

Which of the following is not something commonly found in lean systems?
(I)waste reduction(II)output match to a detailed forecast(III)visual controls(IV)quick changeovers(V)long production runs

A)both I and V
B)both II and V
C)both II and IV
D)both IV and V
E)both III and V

Question 70

Which of the following would not improve the performance of a breakdown program?

A)more trained personnel
B)short lead times for replacement parts
C)standby equipment
D)cross-training repair personnel
E)reducing inventories of spare parts

Question 71

The major approaches used in plans to deal with breakdowns include all of the following except

A)standby equipment.
B)inventories of spare parts.
C)operator repair of minor problems.
D)readily available repair personnel.
E)All are major approaches.

Question 72

"Total productive maintenance" is best described as

A)avoiding all breakdown maintenance.
B)doing a great deal of preventive maintenance to try to avoid breakdown maintenance.
C)a JIT approach in which workers perform preventive maintenance on the machines they operate.
D)extending preventive maintenance back to design.
E)none of these.

Question 73

The total maintenance cost curve (preventive maintenance cost plus breakdown and repair cost)

A)slopes up as the number of preventive maintenances increases.
B)slopes down as the number of preventive maintenances increases.
C)starts low, increases rapidly, and then drops back down as the number of preventive maintenances increases.
D)starts high, drops gradually, but then goes back up as the number of preventive maintenances increases.
E)remains relatively flat as the number of preventive maintenances increases.

Question 74

A reactive approach to maintenance is _____ maintenance.

A)planned
B)breakdown
C)proactive
D)predictive
E)preventive

Question 75

In the area of maintenance, the Pareto phenomenon is reflected in the fact that

A)all equipment justifies about the same expense.
B)a majority of equipment will justify considerable expense.
C)a few pieces of equipment will justify little expense.
D)a few pieces of equipment will justify considerable expense.
E)no piece of equipment will justify major expense; it's better to replace.

Question 76

This is considered an important issue when dealing with preventative maintenance.

A)repair costs
B)frequency
C)seasonality
D)timing of breakdown
E)cost of training

Question 77

Preventive maintenance is generally scheduled on the basis of

A)planned inspections.
B)passage of time.
C)number of operating hours.
D)all of the choices.
E)none of the choices.

Question 78

In the broadest sense, equipment and facilities preventive maintenance extends back to the

A)design and selection stage.
B)procurement stage.
C)installation stage.
D)pilot-testing stage.
E)implementation stage.

Question 79

_____ is known as being a proactive approach to maintenance.

A)Breakdown maintenance
B)Preventative maintenance
C)Predictive maintenance
D)Corrective maintenance
E)Condition-based maintenance

Question 80

Ideally, preventive maintenance will be performed

A)after a planned inspection.
B)after the passage of a specified period of time.
C)after a predetermined number of operating hours.
D)just prior to the start of the workday.
E)just prior to a breakdown or failure.