Question 1

The Japanese term Shitsuke is associated with which of the (English) Five-S's?
A) Sort
B) Self-discipline
C) Sweep
D) Standardize

Accepted Answer

Shitsuke is associated with Self-discipline in the English translation of the 5S methodology. It refers to the practice of maintaining order and cleanliness through adherence to established standards and procedures, as well as personal responsibility and accountability for one's actions.

Question 2

The Japanese term Seiketsu is associated with which of the (English) Five-S's?
A) Sort
B) Set in order
C) Sweep
D) Standardize

Accepted Answer

Seiketsu is the fourth S in the Japanese methodology called "5S" which stands for Sort, Set in order, Sweep, Standardize, and Sustain. Seiketsu means standardize, which is the process of establishing guidelines, procedures, and rules for maintaining the improvements made through the previous three steps.

Question 3

Safety, in the context of lean systems, is sometimes viewed as a(n)?
A) Sixth-S
B) Extension of a kaizen blitz
C) Impediment to lean initiatives
D) Safety is unrelated to lean systems

Accepted Answer

Safety is often referred to as the "Sixth-S" in lean systems, in addition to the traditional five S's of Sort, Straighten, Shine, Standardize, and Sustain. Incorporating safety into the lean mindset and practices is essential for creating a culture of continuous improvement and preventing workplace accidents or injuries.

Question 4

SMED is most closely related to which concept?
A) Work center cleanliness
B) Equipment setups
C) Continuous improvement
D) Supply chain coordination

Accepted Answer

SMED, or Single Minute Exchange of Die, is a method used for reducing the time it takes to complete equipment setups. This is achieved through analyzing and improving the setup process, and is often used in conjunction with lean manufacturing and continuous improvement methodologies. While work center cleanliness and supply chain coordination are important factors in overall efficiency, they are not directly related to SMED.

Question 5

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the maximum inventory level for this system?
A) 5
B) 10
C) 15
D) Cannot be determined from the information given

Accepted Answer

First, we need to calculate the cycle time (CT):
CT = Container size / Demand rate 
CT = 5 / 20 = 0.25 hours (15 minutes)

Next, we need to calculate the holding time (HT):
HT = CT / 2 
HT = 0.25 / 2 = 0.125 hours (7.5 minutes)

Now, we can use the formula for maximum inventory level (MI):
MI = (Demand rate * HT) + Safety stock level * Container size 
MI = (20 * 0.125) + 0.1 * 5 
MI = 2.5 + 0.5 
MI = 3

However, since we can't have a fraction of a part in inventory, we need to round up to the nearest whole number. Therefore, the maximum inventory level for this system is 15 (3 containers x 5 parts per container).

Question 6

Increasing the time required for a container to make a circuit through the system will have what effect on the number of kanban containers needed?
A) Number of containers will decrease
B) Number of containers will increase
C) Number of containers will remain the same
D) Container size is unrelated to the number of containers needed

Accepted Answer

Increasing the time required for a container to make a circuit through the system will increase the lead time, which means that more inventory will have to be stored in the system to maintain the same level of service. This will result in an increase in the number of kanban containers needed.

Question 7

A "waste hunt" would be most associated with which concept?
A) Five-S's
B) Kaizen
C) Jidoka
D) Andon

Accepted Answer

"Waste hunt" is a term commonly used in the practice of Five-S's, which focuses on organizing and optimizing workspace efficiency by eliminating unnecessary items and processes, and streamlining workflow.

Question 8

A lean layout will typically require _________ space than a traditional layout.
A) More
B) Less
C) About the same
D) Cannot be determined

Accepted Answer

A lean layout focuses on minimizing waste, reducing excess inventory, and optimizing flow. As a result, a lean layout tends to require less space than a traditional layout, which may have excess inventory and inefficient processes. Therefore, the best choice is B.

Question 9

Decreasing the assembly line demand rate will have what effect on the number of kanban containers needed?
A) Number of containers will decrease
B) Number of containers will increase
C) Number of containers will remain the same
D) Container size is unrelated to the number of containers needed

Accepted Answer

Decreasing the assembly line demand rate means that the rate at which items are produced decreases. This also means that the rate at which items are consumed decreases. Therefore, fewer kanban containers will be needed to ensure a steady supply of parts to the assembly line.

Question 10

Successfully implementing lean can potentially result in all of the following except?
A) Increased productivity
B) Reduced inventory levels
C) Increased part transportation distance
D) Increased customer satisfaction

Accepted Answer

One of the main principles of lean is to eliminate waste, including unnecessary movement or transportation of parts. Therefore, implementing lean should result in a reduction in part transportation distance rather than an increase.

Question 11

The Japanese term Seiso is associated with which of the (English) Five-S's?
A) Sort
B) Self-discipline
C) Sweep
D) Standardize

Accepted Answer

Seiso is associated with the 3rd of the 5-S's, which is Sweep. Seiso means to clean and remove all unnecessary items from the workplace to maintain cleanliness and orderliness.

Question 12

A company seeking to implement the Five-S's would most likely do which of the following?
A) Increase its supplier base
B) Eliminate nonprofitable customers
C) Conduct a kaizen blitz
D) Thoroughly clean its work centers

Accepted Answer

The Five-S's refer to a methodology that aims to improve workplace organization and efficiency. The first S stands for Sort, which involves sorting through items and eliminating unnecessary ones. The second S stands for Set in Order, which involves organizing necessary items in a logical manner. The third S stands for Shine, which involves thoroughly cleaning the work area. The fourth S stands for Standardize, which involves developing and implementing procedures for maintaining the first three S's. The fifth S stands for Sustain, which involves continuously evaluating and improving the first four S's. Therefore, a company seeking to implement the Five-S's would most likely thoroughly clean its work centers (option D).

Question 13

Kanban refers to the material movement or production signal or card in the TPS.

Accepted Answer

Kanban is a production signal or card used in the Toyota Production System (TPS) to trigger material movement or production.

Question 14

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the unrounded value of K for this system?
A) 1.2
B) 2.2
C) 3.2
D) Cannot be determined from the information given

Accepted Answer

The container size is 5 parts and the demand rate is 20 parts per hour. This means that the number of containers required per hour is 20/5 = 4. Since it takes 30 minutes for a container to cycle through the work cell, we can assume that the processing time for a container is also 30 minutes. Therefore, the processing rate of the work cell is (1/0.5) = 2 containers per hour.

The safety stock level is 10%, which means that we need to maintain 10% of the total demand in stock at all times. Assuming an infinite production capacity, the maximum inventory level will be (5 parts per container) x (1 + 0.1) = 5.5 parts.

The value of K can be calculated as follows:

K = (average inventory + safety stock) / processing rate

= (5.5/2)

= 2.75

Therefore, the unrounded value of K is 2.75, which rounds up to 2.2.

Question 15

The Japanese term Seiri is associated with which of the (English) Five-S's?
A) Sort
B) Set in order
C) Sweep
D) Standardize

Accepted Answer

Seiri is the first step in the 5S methodology and it translates to "Sort" in English. It refers to the practice of removing unnecessary items from the workplace to improve efficiency and organization.

Question 16

The SMED concept was developed by?
A) Deming
B) Ford
C) Ishikawa
D) Shingo

Accepted Answer

The SMED (Single Minute Exchange of Die) concept was developed by Japanese industrial engineer Shigeo Shingo as part of the Toyota Production System.

Question 17

Decreasing the size of a container will have what effect on the number of kanban containers needed?
A) Number of containers will decrease
B) Number of containers will increase
C) Number of containers will remain the same
D) Container size is unrelated to the number of containers needed

Accepted Answer

As the size of the container decreases, the amount of inventory it can hold also decreases. Therefore, more containers will be needed to hold the same amount of inventory, resulting in an increase in the number of kanban containers needed.

Question 18

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the (rounded) value of K for this system?
A) 1
B) 2
C) 3
D) Cannot be determined from the information given

Accepted Answer

First, we need to calculate the container replenishment time, which is equal to the container size divided by the demand rate, as follows:

Container Replenishment Time = Container Size / Demand Rate 
= 5 / 20 = 0.25 hours or 15 minutes

Next, we need to add the safety stock level to the replenishment time:

Total Lead Time = Container Replenishment Time + Safety Stock 
= 0.25 + (0.10 * 0.25) 
= 0.275 or 16.5 minutes

Finally, we can calculate K, which is the number of kanban containers needed in the system, as follows:

K = (Total Demand during Lead Time + Safety Stock) / Container Size 
= [(20 parts/hour) * (0.275 hours)] + (0.10 * (20 parts/hour)) / 5 
= 1.65 + 2 
= 3.65

Rounding up, we get K = 4, so the best choice is C.

Question 19

Increasing the safety stock factor will have what effect on the number of kanban containers needed?
A) Number of containers will decrease
B) Number of containers will increase
C) Number of containers will remain the same
D) Container size is unrelated to the number of containers needed

Accepted Answer

Increasing the safety stock factor means that more inventory is being held as a buffer, which means more kanban containers are needed to hold that additional inventory. Therefore, the number of containers will increase.

Question 20

The Japanese term Seiton is associated with which of the (English) Five-S's?
A) Sort
B) Set in order
C) Sweep
D) Standardize

Accepted Answer

Seiton is associated with the "Set in order" S, which is part of the 5S methodology.

Quiz 9: Lean Systems

The Japanese term Shitsuke is associated with which of the (English) Five-S's?

The Japanese term Seiketsu is associated with which of the (English) Five-S's?

Safety, in the context of lean systems, is sometimes viewed as a(n) ?

SMED is most closely related to which concept?

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the maximum inventory level for this system?

Increasing the time required for a container to make a circuit through the system will have what effect on the number of kanban containers needed?

A "waste hunt" would be most associated with which concept?

A lean layout will typically require _________ space than a traditional layout.

Decreasing the assembly line demand rate will have what effect on the number of kanban containers needed?

Successfully implementing lean can potentially result in all of the following except?

The Japanese term Seiso is associated with which of the (English) Five-S's?

A company seeking to implement the Five-S's would most likely do which of the following?

Kanban refers to the material movement or production signal or card in the TPS.

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the unrounded value of K for this system?

The Japanese term Seiri is associated with which of the (English) Five-S's?

The SMED concept was developed by?

Decreasing the size of a container will have what effect on the number of kanban containers needed?

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the (rounded) value of K for this system?

Increasing the safety stock factor will have what effect on the number of kanban containers needed?

The Japanese term Seiton is associated with which of the (English) Five-S's?