Question 1

A company has successfully implemented Lean practices in their three station process. The stations are, in order, Station A, Station B, and Station C and product moves from A to B to C smoothly. One day, the equipment at Station B experiences catastrophic failure. What happens and what is the appropriate response for a Lean-thinking company?
A)Continue producing at Station C and restore capacity at Station B.
B)Continue producing at Station A and restore capacity at Station B.
C)Continue producing at Station A and C and restore capacity at Station B.
D)Everything stops and attention is focused on restoring capacity at Station B.

Accepted Answer

In Lean thinking, the focus is on flow and minimizing waste. When a station in the process experiences a failure, continuing production at other stations can lead to overproduction, which is a form of waste. The appropriate response is to stop and focus efforts on restoring the failed station to resume the smooth flow of production.

Question 2

Lean's focus on inventory reduction prioritizes raw materials as most important to reduce, followed by work in process and finally finished goods.

Accepted Answer

Lean focuses on reducing all types of inventory, but it particularly emphasizes minimizing work in process (WIP) inventory to streamline production and reduce waste, rather than prioritizing raw materials or finished goods specifically.

Question 3

In the water and rocks analogy for Lean:
A)water represents problems.
B)water represents inventory.
C)rocks represent inventory.
D)water wears away rocks gradually just like continuous improvement programs improve quality.

Accepted Answer

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Question 4

A typical application of Lean would call for a gradual reduction in system inventory until a problem surfaces. Once this problem is fixed, the cycle begins again, i.e., inventory is reduced until another problem is surfaced and fixed.

Accepted Answer

This is a key principle behind the Lean philosophy of continuous improvement, or Kaizen. By gradually reducing inventory and addressing problems as they arise, organizations can improve their efficiency, quality, and customer satisfaction over time.

Question 5

What is the difference between Lean and kanban?

Accepted Answer

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Question 6

________ could result in workers from one company working to eliminate waste for a company from which they purchase components.

Accepted Answer

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Question 7

One recent development in Lean thinking is the combination of Lean and Six Sigma into Lean Six Sigma, which combines the rigor of statistical analysis and DMAIC approach with Lean's focus on waste reduction.

Accepted Answer

Lean Six Sigma is a combination of both Lean and Six Sigma methodologies. It combines the waste reduction focus of Lean and the statistical analysis and DMAIC approach of Six Sigma.

Question 8

In a lean system when a process is running smoothly:
A)workers are underutilized.
B)there is too little inventory in the system.
C)there is too much inventory in the system.
D)workers are overutilized.

Accepted Answer

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Question 9

Provide a definition by description of the Lean philosophy. Where can Lean be deployed?

Accepted Answer

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Question 10

A reduction in inventory levels forces a company to address poor manufacturing practices.

Accepted Answer

When inventory levels are reduced, it puts pressure on a company to improve its manufacturing practices in order to address the inefficiencies and increase productivity. This requires streamlining processes, improving quality control, and reducing waste. In short, reducing inventory levels can help a company identify and address any inefficiencies in its manufacturing practices.

Question 11

In a two-card kanban system:
A)the production card signals when a move card should be moved to the next process step.
B)the move card signals when a container of parts should be produced.
C)the production card signals when a container that held parts should be returned to inventory.
D)the move card signals when a container of parts should move to the next process step.

Accepted Answer

In a two-card kanban system, the move card signals when a container of parts should move to the next process step. The production card is used to signal when a container that held parts should be returned to inventory.

Question 12

A kanban can be:
A)a container.
B)a card.
C)a visual cue.
D)All of these can be kanbans.

Accepted Answer

All of these can be kanbans. A kanban can refer to a physical container, a card used to signal when inventory needs to be replenished, or a visual cue such as a sign that displays the status of a process.

Question 13

Once a system has been "leaned out" with all excess inventory removed, if a piece of production equipment breaks, all activity on the production line ________.

Accepted Answer

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Question 14

Lean Six Sigma combines the organizational elements and tools of Lean with the broad focus on waste reduction of Six Sigma.

Accepted Answer

Lean Six Sigma combines the process improvement tools of Lean, which focuses on waste reduction, with the statistical tools of Six Sigma, which focuses on reducing variation and improving quality.

Question 15

Lean supply chain management also seeks to optimize flows of information and money in addition to physical flows.

Accepted Answer

Lean supply chain management aims to optimize all aspects of the supply chain, including information and financial flows, in order to reduce waste and improve efficiency.

Question 16

The analogy of rocks in a river is often used when discussing Lean principles. In the analogy, the rocks represent ________ while the water represents ________.

Accepted Answer

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Question 17

Lean supply chain management focuses on eliminating waste:
A)in a firm's sourcing and logistics activities.
B)within a firm's internal operations.
C)in flows of information and money among supply chain partners.
D)in all of the above areas.

Accepted Answer

Lean supply chain management aims to eliminate waste in all areas including a firm's sourcing and logistics activities, within a firm's internal operations, and flows of information and money among supply chain partners. This approach streamlines processes and reduces costs, ultimately leading to improved efficiency and increased customer satisfaction.

Question 18

________ combines the focus on waste reduction with the discipline of define, measure, analyze, improve, and control.

Accepted Answer

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Question 19

What is the Lean perspective on inventory?

Accepted Answer

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Question 20

Recent developments in Lean thinking have combined these principles with Six Sigma and with supply chain management. Pick either one of these programs and describe its elements. Then provide an example from current business news of an operation or supply chain that has embraced these principles.

Accepted Answer

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Quiz 13: Jitlean Production

Lean's focus on inventory reduction prioritizes raw materials as most important to reduce, followed by work in process and finally finished goods.

In the water and rocks analogy for Lean: