Question 1

The cook in a fast-food restaurant knows that 2 hamburger patties and an order of fries should be started for each car that is waiting in line. This is best an example of

Accepted Answer

A)  Lead time 
B)  Kanban 
C)  Push production 
D)  Kaizen 
E)  EOQ 
A)  Lead time 
B)  Kanban 
C)  Push production 
D)  Kaizen 
E)  EOQ

Question 2

JIT brings about competitive advantage by faster response to the customer regardless of cost.

Accepted Answer

A) True 
 B)False

Question 3

Which of the following is specifically characterized by the elimination of waste through a focus on exactly what the customer wants?

Accepted Answer

A)  Just-in-time (JIT) 
B)  Toyota Production System (TPS) 
C)  Lean operations 
D)  Material requirements planning (MRP) 
E)  kanban 
A)  Just-in-time (JIT) 
B)  Toyota Production System (TPS) 
C)  Lean operations 
D)  Material requirements planning (MRP) 
E)  kanban

Question 4

If the goals of JIT partnerships are met, which of the following is a result?

Accepted Answer

A)  For incoming goods, receiving activity and inspection are outsourced. 
B)  In-transit inventory falls as suppliers are located closer to facilities. 
C)  The number of suppliers increases. 
D)  In-plant inventory replaces in-transit inventory. 
E)  All of the above are consequences of meeting the JIT partnership goals. 
A)  For incoming goods, receiving activity and inspection are outsourced. 
B)  In-transit inventory falls as suppliers are located closer to facilities. 
C)  The number of suppliers increases. 
D)  In-plant inventory replaces in-transit inventory. 
E)  All of the above are consequences of meeting the JIT partnership goals.

Question 5

A bakery uses 9 containers that each hold 6 cakes. If daily demand is 40 cakes and lead time is 1 day determine the safety stock.

Accepted Answer

9 = (40 +

Question 6

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 7

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 8

Which of the following statements regarding a pull system is true?

Accepted Answer

A)  Large lots are pulled from upstream stations. 
B)  Work is pulled to the downstream stations before it is actually needed. 
C)  Manufacturing cycle time is increased. 
D)  Problems become more obvious. 
E)  None of the above are true of a pull system. 
A)  Large lots are pulled from upstream stations. 
B)  Work is pulled to the downstream stations before it is actually needed. 
C)  Manufacturing cycle time is increased. 
D)  Problems become more obvious. 
E)  None of the above are true of a pull system.

Question 9

Which one of the following scenarios represents the use of a kanban to reduce inventories?

Accepted Answer

A)  A supervisor tells the operators to stay busy and start producing parts for next month. 
B)  A "supplier" work centre signals the downstream workstation that a batch has been completed. 
C)  A supervisor signals to several work centres that the production rate should be changed. 
D)  A "customer" work centre signals to the "supplier" workstation that more parts are needed. 
E)  An operator asks the next station's operator to help him fix his machine. 
A)  A supervisor tells the operators to stay busy and start producing parts for next month. 
B)  A "supplier" work centre signals the downstream workstation that a batch has been completed. 
C)  A supervisor signals to several work centres that the production rate should be changed. 
D)  A "customer" work centre signals to the "supplier" workstation that more parts are needed. 
E)  An operator asks the next station's operator to help him fix his machine.

Question 10

Which of the following is the author of the phrase "Inventory is evil"?

Accepted Answer

A)  Poka Yoke 
B)  Pat "Keiretsu" Morita 
C)  Kanban Polka 
D)  Shigeo Shingo 
E)  Henry Ford 
A)  Poka Yoke 
B)  Pat "Keiretsu" Morita 
C)  Kanban Polka 
D)  Shigeo Shingo 
E)  Henry Ford

Question 11

What three things does the Toyota Production System (TPS) emphasize?

Accepted Answer

Focus on continuous

Question 12

Labor cost for set-up is $500/hour. If the plant plans on level material use and operates 50 days per year, determine the time it takes to setup.
 $$\begin{array} { | l | l | } 
\hline \text { Annual demand } & 5000 \
\hline \text { Daily production } & 1000 \
\hline \text { Lot size } & 700 \
\hline \text { Holding cost } & \$ 25 \
\hline
\end{array}$$

Accepted Answer

S = Q² x H ∗ (1 - d/p)/(2D) = 7

Question 13

A bakery uses 5 containers that hold 3 cakes. Daily demand is 10 cakes and safety stock is 5 cakes. What is the lead time?

Accepted Answer

5 = (5 + 1

Question 14

Lean operations are known for their

Accepted Answer

A)  employee development. 
B)  supplier education. 
C)  supplier partnerships. 
D)  challenging jobs. 
E)  All of the above are attributes of lean operations. 
A)  employee development. 
B)  supplier education. 
C)  supplier partnerships. 
D)  challenging jobs. 
E)  All of the above are attributes of lean operations.

Question 15

Which of the following statements regarding JIT in services is true?

Accepted Answer

A)  Restaurants do not use JIT layouts because they interfere with creation of a good servicescape. 
B)  Excess customer demand in services such as air travel is met by dipping into safety stocks. 
C)  All of the JIT techniques for dealing with suppliers, layout, inventory, and scheduling are used in services. 
D)  Scheduling is not relevant to effective use of JIT in services. 
E)  Stockbrokers keep a high level of inventory. 
A)  Restaurants do not use JIT layouts because they interfere with creation of a good servicescape. 
B)  Excess customer demand in services such as air travel is met by dipping into safety stocks. 
C)  All of the JIT techniques for dealing with suppliers, layout, inventory, and scheduling are used in services. 
D)  Scheduling is not relevant to effective use of JIT in services. 
E)  Stockbrokers keep a high level of inventory.

Question 16

Just-in-time systems make demands on layouts, including

Accepted Answer

A)  distance reduction. 
B)  increased flexibility. 
C)  reduced space and inventory. 
D)  cross-trained, flexible employees. 
E)  All of the above are JIT influences on layout. 
A)  distance reduction. 
B)  increased flexibility. 
C)  reduced space and inventory. 
D)  cross-trained, flexible employees. 
E)  All of the above are JIT influences on layout.

Question 17

________ is a JIT concept that results in material being produced only when requested and moved to where it is needed just as it is needed.

Accepted Answer

The answer of ________ is a JIT concept that results...

Question 18

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

Accepted Answer

A)  overproduction 
B)  transportation 
C)  assignment 
D)  defective product 
E)  motion 
A)  overproduction 
B)  transportation 
C)  assignment 
D)  defective product 
E)  motion

Question 19

Lead time for computers is 5 days with daily demand of 25 and safety stock of 5 computers. If management wants to use 10 kanbans how many computers should each one hold?

Accepted Answer

A)  not enough information 
B)  1 
C)  5 
D)  10 
E)  13 
A)  not enough information 
B)  1 
C)  5 
D)  10 
E)  13

Question 20

The Toyota Production System requires that activities have built-in, automatic tests so that gaps between expectations and actuality are immediately evident.

Accepted Answer

A) True 
 B)False

Exam 16: Lean Operations

The cook in a fast-food restaurant knows that 2 hamburger patties and an order of fries should be started for each car that is waiting in line. This is best an example of

JIT brings about competitive advantage by faster response to the customer regardless of cost.

Which of the following is specifically characterized by the elimination of waste through a focus on exactly what the customer wants?

If the goals of JIT partnerships are met, which of the following is a result?

A bakery uses 9 containers that each hold 6 cakes. If daily demand is 40 cakes and lead time is 1 day determine the safety stock.

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.

Manufacturing cycle time is best defined as the

Which of the following statements regarding a pull system is true?

Which one of the following scenarios represents the use of a kanban to reduce inventories?

Which of the following is the author of the phrase "Inventory is evil"?

What three things does the Toyota Production System (TPS) emphasize?

Labor cost for set-up is $500/hour. If the plant plans on level material use and operates 50 days per year, determine the time it takes to setup. Annual demand 5000 Daily production 1000 Lot size 700 Holding cost \ 25

A bakery uses 5 containers that hold 3 cakes. Daily demand is 10 cakes and safety stock is 5 cakes. What is the lead time?

Lean operations are known for their

Which of the following statements regarding JIT in services is true?

Just-in-time systems make demands on layouts, including

________ is a JIT concept that results in material being produced only when requested and moved to where it is needed just as it is needed.

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

Lead time for computers is 5 days with daily demand of 25 and safety stock of 5 computers. If management wants to use 10 kanbans how many computers should each one hold?

The Toyota Production System requires that activities have built-in, automatic tests so that gaps between expectations and actuality are immediately evident.

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