Question 1

Which of the following is NOT consistent with the lean philosophy?

Accepted Answer

Increasing batch size goes against the lean philosophy, which aims to minimize waste and achieve flow by producing in small batches. Large batches result in excess inventory, longer lead times, and decreased flexibility. The other options are consistent with the lean philosophy, as cross-training employees increases flexibility, developing a culture of continuous improvement fosters a mindset of waste reduction, and positioning WIP inventories near each processing center helps to reduce lead times and improve flow.

Question 2

Which of the following best describes the five S's?

Accepted Answer

The five S's refer to a methodology that originated in Japan, focusing on workplace organization and standardization to improve efficiency, safety, and cleanliness. The terms are Seiri, Seiton, Seiso, Seiketsu, and Shitsuke, which translate to Sort, Set in order, Shine, Standardize, and Sustain, respectively.

Question 3

Efficient Consumer Response was initially developed in the 1990's for the following industry:

Accepted Answer

Efficient Consumer Response (ECR) was initially developed in the 1990s for the grocery industry. It is a strategy that aims to improve the efficiency of the grocery supply chain and enhance customer satisfaction by focusing on collaboration and sharing information among retailers, manufacturers, and suppliers.

Question 4

Lean production systems are sometimes referred to as pull systems because demand from customers activates the production actions of the manufacturing facilities.In order for this demand to be communicated to everyone in the supply chain/manufacturing facility a signal must be passed from downstream processing centers to the upstream processing centers.This system of relaying signals is referred to as a:

Accepted Answer

The system of relaying signals from downstream to upstream processing centers in a lean production system is referred to as a kanban system. Kanban cards or signals are used to indicate when more materials or goods need to be produced or delivered to the next processing center based on the demand from the customer. This helps to avoid overproduction and excess inventory, as production is only triggered by actual demand. Semaphore systems refer to visual signaling devices used for communication, while keiretsu networks and TQM networks are not directly related to the process of relaying demand signals in lean production systems.

Question 5

Which of the following are among the MOST important elements of the lean production philosophy?

Accepted Answer

The answer of Which of the following are among the...

Question 6

Which of the following layouts is primarily designed to process parts,components,or jobs requiring the same or similar processing steps,saving duplication of equipment and labor:

Accepted Answer

Manufacturing cells are designed to process parts, components, or jobs requiring the same or similar processing steps. This helps to save duplication of equipment and labor. Work centers, production kanban, and work-in-process are not primarily designed for this purpose.

Question 7

The Quick Response program,developed in the 1980's,was an offshoot of the following supply chain concept:

Accepted Answer

The Quick Response program was developed as an offshoot of the Just-in-Time (JIT) supply chain concept, which focuses on reducing inventory levels and increasing efficiency by receiving goods only as they are needed in the production process.

Question 8

The common term across the seven wastes is:

Accepted Answer

The common term across the seven wastes is "excess". The seven wastes are overproduction, waiting, transport, overprocessing, excess inventory, excess motion, and defects. All of these wastes involve some form of excess, whether it be excess materials, time, or effort. Therefore, choice C is the best answer.

Question 9

Lean production emphasizes all of the following EXCEPT:

Accepted Answer

Lean production emphasizes the reduction of waste, synchronization of material flows, and continuous improvement. However, it does not emphasize large batch sizes, as this goes against the principle of reducing waste and increasing efficiency. In fact, lean production encourages the use of smaller batch sizes to reduce overproduction and excess inventory. Therefore, option D is the correct answer as it goes against the principles of lean production.

Question 10

The following is a term that refers to error- or mistake proofing:

Accepted Answer

Poka-yoke is a Japanese term that refers to mistake-proofing or error-proofing a process through the use of tools, techniques, and devices. It aims to prevent defects from occurring or detect them as soon as possible to minimize their impact. Poka-yoke is an important part of Lean Manufacturing and Six Sigma methodologies.

Question 11

Which of the following quality gurus believed that companies should strive for zero defects and that quality was,in a sense,free since quality improvement programs invariably paid for themselves?

Accepted Answer

The quality guru who believed that companies should strive for zero defects and that quality was, in a sense, free since quality improvement programs invariably paid for themselves was Philip Crosby. Therefore, the correct choice is D.

Question 12

When compared to their U.S.counterparts,a benchmarking study found that Japanese auto manufacturers used:

Accepted Answer

The benchmarking study found that Japanese auto manufacturers used half the manufacturing labor, half the space, and half the engineering hours to produce a new automobile model when compared to their U.S. counterparts. Therefore, option D - "All of the above" is the correct choice.

Question 13

Which of the following is NOT one of the Seven Wastes?

Accepted Answer

The Seven Wastes, also known as Muda, are a core concept in Lean manufacturing and include: Overproduction, Waiting time, Transportation, Processing, Motion, Excess inventories, and Scrap and rework. Environmental waste is not a recognized category of waste in Lean manufacturing.

Question 14

Japanese manufacturing firms sometimes create cooperative coalitions with their suppliers in order to provide the suppliers with a certain degree of financial support.What are these cooperative coalitions called?

Accepted Answer

Cooperative coalitions between Japanese manufacturing firms and their suppliers are called Keiretsu Networks.

Question 15

Which company probably played the largest role in the development of the Toyota Production System?

Accepted Answer

Ford's production system, known as Fordism, heavily influenced the development of the Toyota Production System. Specifically, Toyota was impressed by Ford's focus on minimizing waste and optimizing efficiency in production. Toyota then adapted and improved upon these concepts to create their own system, which became known as the Toyota Production System or Lean Manufacturing. While other companies, such as GM and Chrysler, also developed their own production systems, it was Ford's influence that played the largest role in shaping the Toyota Production System. Boeing does not have a significant connection to the development of the Toyota Production System.

Question 16

Lean thinking is a philosophy incorporating tools which seek to economically optimize:

Accepted Answer

Lean thinking aims to optimize all aspects of a process, including human resources, assets, and productivity. Therefore, the best choice is D as it encompasses all three areas.

Question 17

An integral part of Six Sigma is:

Accepted Answer

Six Sigma is a methodology for improving business processes by reducing defects and minimizing variability. An integral part of Six Sigma is a commitment to continuous improvement and the use of data to drive decision making. This is why firms commit to a program of continual reassessment and improvement when implementing Six Sigma. The other choices, such as ABC analysis or ERP, may be useful tools for improving processes and reducing waste, but they are not necessarily integral to Six Sigma.

Question 18

Calculate the inventory container size required given the following:
Demand rate = 10 parts per hour,Safety stock required = 15%
Number of containers = 14,Time to cycle through entire system = 6 hours

Accepted Answer

The inventory container size can be calculated using the formula: Container Size = (Demand Rate * Time to Cycle * (1 + Safety Stock)) / Number of Containers. Plugging in the values: (10 parts/hour * 6 hours * 1.15) / 14 containers = 5 parts per container.

Question 19

Calculate the defects per million opportunities (DPMO)given the following:
Blake,owner of Blakester's T-shirt Shoppe,keeps track of customer complaints.For each T-shirt sold,there are four possible complaints: T-shirt shrinks,poor quality,design wears off,and doesn't fit right.Each week,Blake calculates the rate of T-shirt "defects" per total T-shirts sold,and then uses this information to determine his company's DPMO.During the past week,his company sold 1200 T-shirts.His company received 22 customer shrinkage complaints,16 poor quality complaints,12 design wears off complaints,8 doesn't fit right complaints.
Calculate his firm's DPMO.

Accepted Answer

To calculate DPMO (Defects Per Million Opportunities), you first determine the total number of defects, then divide by the total number of opportunities (in this case, opportunities for defects), and finally multiply by 1,000,000. Here, the total defects are 22 (shrinkage) + 16 (poor quality) + 12 (design wears off) + 8 (doesn't fit right) = 58 defects. Each T-shirt sold represents 4 opportunities for defects (one for each type of complaint), so with 1200 T-shirts sold, there are 1200 * 4 = 4800 opportunities. Thus, DPMO = (58 / 4800) * 1,000,000 = 12,083.

Question 20

Which of the following is an example of how lean programs can help to protect the environment?:

Accepted Answer

All of the listed options are examples of how lean programs can help to protect the environment. Parts made from recycled materials and using rubber from used tires in auto parts reduce waste and promote recycling. Batch size reduction helps to reduce the amount of plastic waste generated in the manufacturing process. Overall, lean programs focus on reducing waste and improving efficiency, which can ultimately lead to a reduction in the use of natural resources and environmental impact.

Quiz 8: Process Management - Lean and Six Sigma in the Supply Chain