Question 1

Variability in manufacturing can occur because engineering drawings or specifications are incomplete or inaccurate.

Accepted Answer

A) True 
 B)False

Question 2

Which of the following is NOT an attribute of lean operations?

Accepted Answer

A) eliminating almost all inventory through just-in-time techniques 
B) minimizing space requirements by reducing the distance a part travels 
C) pushing responsibility to the highest level possible through centralized decision making 
D) educating suppliers to accept responsibility for helping meet customer needs 
E) building worker flexibility through cross-training and reducing job classifications 
A) eliminating almost all inventory through just-in-time techniques 
B) minimizing space requirements by reducing the distance a part travels 
C) pushing responsibility to the highest level possible through centralized decision making 
D) educating suppliers to accept responsibility for helping meet customer needs 
E) building worker flexibility through cross-training and reducing job classifications

Question 3

Just-in-time systems make demands on layouts,including the need for:

Accepted Answer

A) distance reduction. 
B) increased flexibility. 
C) reduced space and inventory. 
D) cross-trained,flexible employees. 
E) all of the above 
A) distance reduction. 
B) increased flexibility. 
C) reduced space and inventory. 
D) cross-trained,flexible employees. 
E) all of the above

Question 4

Which of the following is generally found in most lean environments?

Accepted Answer

A) a push or pull system,depending upon the rate of demand 
B) a push system for high margin items and a pull system for low margin items 
C) a push system for purchased parts and a pull system for manufactured parts 
D) push systems 
E) pull systems 
A) a push or pull system,depending upon the rate of demand 
B) a push system for high margin items and a pull system for low margin items 
C) a push system for purchased parts and a pull system for manufactured parts 
D) push systems 
E) pull systems

Question 5

Manufacturing cycle time is best defined as the:

Accepted Answer

A) length of the work shift,expressed in minutes per day. 
B) time it takes a unit to move from one workstation to the next. 
C) time between the start of one unit and the start of the next unit. 
D) sum of all the task times to make one unit of a product. 
E) time from raw materials receipt to finished product exit. 
A) length of the work shift,expressed in minutes per day. 
B) time it takes a unit to move from one workstation to the next. 
C) time between the start of one unit and the start of the next unit. 
D) sum of all the task times to make one unit of a product. 
E) time from raw materials receipt to finished product exit.

Question 6

Which one of the following is NOT a layout tactic in a JIT environment?

Accepted Answer

A) work cells for families of products 
B) fixed equipment 
C) minimizing distance 
D) little space for inventory 
E) poka-yoke devices 
A) work cells for families of products 
B) fixed equipment 
C) minimizing distance 
D) little space for inventory 
E) poka-yoke devices

Question 7

Level scheduling means producing at a constant rate,regardless of customer demands.

Accepted Answer

A) True 
 B)False

Question 8

JIT makes quality cheaper because:

Accepted Answer

A) the cost of low quality can be hidden as inventory cost. 
B) JIT adds more buffers to the system. 
C) JIT prevents long runs of defects. 
D) B and C 
E) A,B and C 
A) the cost of low quality can be hidden as inventory cost. 
B) JIT adds more buffers to the system. 
C) JIT prevents long runs of defects. 
D) B and C 
E) A,B and C

Question 9

How are lean operations and the Toyota Production System (TPS)alike? How are they different?

Accepted Answer

Lean operations and TPS are basically sy

Question 10

A bakery uses 6 kanban containers that each hold 4 cakes.If safety stock is 2 cakes and lead time is 11 days,determine daily demand.

Accepted Answer

6 = (2 + 1

Question 11

Which of the following is FALSE regarding the links between JIT and quality?

Accepted Answer

A) Inventory hides bad quality;JIT immediately exposes it. 
B) JIT reduces the number of potential sources of error by shrinking queues and lead times. 
C) As quality improves,fewer inventory buffers are needed;in turn,JIT performs better. 
D) If consistent quality exists,JIT allows firms to reduce all costs associated with inventory. 
E) JIT increases the cost of obtaining good quality. 
A) Inventory hides bad quality;JIT immediately exposes it. 
B) JIT reduces the number of potential sources of error by shrinking queues and lead times. 
C) As quality improves,fewer inventory buffers are needed;in turn,JIT performs better. 
D) If consistent quality exists,JIT allows firms to reduce all costs associated with inventory. 
E) JIT increases the cost of obtaining good quality.

Question 12

The 5Ss-sort/segregate,simplify/straighten,shine/sweep,standardize,and sustain/self discipline-are important to lean production because they act as a means to reduce waste.

Accepted Answer

A) True 
 B)False

Question 13

A push system means providing the next station with exactly what is needed when it is needed.

Accepted Answer

A) True 
 B)False

Question 14

If a factory wants to cut its current lot size in half,by what proportion must setup cost change?

Accepted Answer

A) Setup cost must be cut to one fourth its current value. 
B) Setup cost must also be cut in half from its current value. 
C) Setup cost must double from its current value. 
D) Cannot be determined. 
E) Setup cost must quadruple from its current value. 
A) Setup cost must be cut to one fourth its current value. 
B) Setup cost must also be cut in half from its current value. 
C) Setup cost must double from its current value. 
D) Cannot be determined. 
E) Setup cost must quadruple from its current value.

Question 15

A kanban system requires that the process has little variability in lead time because shortages impact the entire production system.

Accepted Answer

A) True 
 B)False

Question 16

The first step in reducing setup times is the separation of setup into preparation activities and actual setup,so that as much work as possible can be done while the machine or process is operating.

Accepted Answer

A) True 
 B)False

Question 17

________ allows manufacturing work cells and offices to be easily rearranged.

Accepted Answer

The answer of ________ allows manufacturing work cells and offices...

Question 18

Which of the following is NOT a concern of suppliers as they prepare to enter into JIT partnerships?

Accepted Answer

A) Suppliers feel that they would be less at risk if they contracted with more than one customer. 
B) Suppliers are concerned that customers will present frequent engineering changes with inadequate lead time to deal with them. 
C) Suppliers feel that their processes are suited for larger lot sizes than the customer wants. 
D) Suppliers are concerned that frequent delivery of small quantities is economically prohibitive. 
E) All of the above represent JIT supplier concerns. 
A) Suppliers feel that they would be less at risk if they contracted with more than one customer. 
B) Suppliers are concerned that customers will present frequent engineering changes with inadequate lead time to deal with them. 
C) Suppliers feel that their processes are suited for larger lot sizes than the customer wants. 
D) Suppliers are concerned that frequent delivery of small quantities is economically prohibitive. 
E) All of the above represent JIT supplier concerns.

Question 19

Weekly usage of a product is 8 units.Since the plant operates 50 weeks per year,this leads to annual usage of 400 units.Setup cost is $40 and annualized carrying cost is $80.Weekly production of this product is 12 units.Lead time is four weeks,and safety stock is one week's production.What is optimal kanban size? What is the optimal number of kanbans?

Accepted Answer

The answer of Weekly usage of a product is 8...

Question 20

A repetitive manufacturing firm is planning on level material use.The following information has been collected.Currently,the firm operates 250 days per year.
   a.What is the setup cost,based on the desired lot size?
b.What is the setup time,based on $40 per hour setup labor?

Accepted Answer

(a)S = @#IMG-DLM& leads to = @#IMG-DLM&

Exam 16: Jit,tps,and Lean Operations

Variability in manufacturing can occur because engineering drawings or specifications are incomplete or inaccurate.

Which of the following is NOT an attribute of lean operations?

Just-in-time systems make demands on layouts,including the need for:

Which of the following is generally found in most lean environments?

Manufacturing cycle time is best defined as the:

Which one of the following is NOT a layout tactic in a JIT environment?

Level scheduling means producing at a constant rate,regardless of customer demands.

JIT makes quality cheaper because:

How are lean operations and the Toyota Production System (TPS)alike? How are they different?

A bakery uses 6 kanban containers that each hold 4 cakes.If safety stock is 2 cakes and lead time is 11 days,determine daily demand.

Which of the following is FALSE regarding the links between JIT and quality?

The 5Ss-sort/segregate,simplify/straighten,shine/sweep,standardize,and sustain/self discipline-are important to lean production because they act as a means to reduce waste.

A push system means providing the next station with exactly what is needed when it is needed.

If a factory wants to cut its current lot size in half,by what proportion must setup cost change?

A kanban system requires that the process has little variability in lead time because shortages impact the entire production system.

The first step in reducing setup times is the separation of setup into preparation activities and actual setup,so that as much work as possible can be done while the machine or process is operating.

________ allows manufacturing work cells and offices to be easily rearranged.

Which of the following is NOT a concern of suppliers as they prepare to enter into JIT partnerships?

A repetitive manufacturing firm is planning on level material use.The following information has been collected.Currently,the firm operates 250 days per year. a.What is the setup cost,based on the desired lot size? b.What is the setup time,based on $40 per hour setup labor?

Operations and Productivity

Operations Strategy in a Global Environment

Project Management

Forecasting

Design of Goods and Services

Managing Quality

Process Strategy

Location Strategies

Layout Strategies

Human Resources,job Design,and Work Measurement

Supply Chain Management

Inventory Management

Aggregate Planning and Sop

Material Requirements Planning Mrpand Erp

Short-Term Scheduling

Maintenance and Reliability

Sustainability in the Supply Chain

Statistical Process Control

Capacity and Constraint Management

Supply Chain Management Analytics

Decision-Making Tools

Linear Programming

Transportation Models

Waiting-Line Models

Learning Curves

Simulation

Filters