Exam 17: Lean Operating Systems

Create & Sell Manufacturing Inc. uses a Kanban system for a component. The daily demand is 175 units. Each container has a combined waiting and processing time of 0.20 days. If the container size is 10 brackets and the safety factor is 11 percent, how many Kanban card sets should be authorized?

Total productive maintenance (TPM) seeks to reduce worker ownership of production equipment by excluding employees from maintenance activities.

A manufacturer of automobile engines is designing a new Kanban system for engine #321. The demand for #321 is 75 parts per day, and the container can hold 8 parts at a time. The total processing and waiting time is 3 days. The manager wants a safety factor ( α ) of 2 or 200 percent. How many Kanbans are required in this system?

Which of the following is a difference between lean production and Six Sigma

Lean Six Sigma focuses on real dollar savings and has the ability to make significant financial impacts on an organization.

In the context of the major categories of waste classified by the Toyota Motor Company, which of the following is true of overproduction

In the context of Kanban systems, a withdrawal Kanban authorizes the gateway workstation to produce parts.

A__________produces finished-goods inventory in advance of customer demand using a forecast of sales.

In the context of the 5S principles, _____ means to keep a process going through training, communication, and organizational structures.

Which of the following is an example of waste in organizations

Kanban is a Japanese word that means elimination of waste.

Long setup times enable a manufacturer to have frequent changeovers and move toward single-piece flow, thus achieving high flexibility and product variety.

Which of the following is a similarity between lean production and Six Sigma

Drive-in-Style Motors follows a traditional manufacturing system. It produces a fixed number of cars every month. It is now planning to switch to a system of manufacturing where workers go to the source of required parts and withdraw them based on requirements. In this scenario, which of the following is most likely to occur if Drive-in-Style Motors implements this plan?

In the context of the 5S principles, _____ refers to ensuring that each item in a workplace is in its proper place or identified as unnecessary and removed.

A hinge manufacturing company employs a Kanban system for a component part. The daily demand is 900 hinges. Each container has a waiting time of 0.05 days and a processing time of 0.37 days. The container size is 60 hinges, and the safety factor (α) is 10 percent. Given this data, the number of Kanbans necessary for the system is:

In the context of lean tools and approaches, _____ are indicators for operating activities that are placed in plain sight of all employees so that everyone can quickly and easily understand the status and performance of the work system.

Any activity, material, or operation that does not add value in an organization is considered waste.

A company is using a Kanban system with 2 containers, each holding 50 parts, between a downstream (using) and an upstream (producing) work center. The using work center can handle 250 jobs per day. The average elapsed time for the entire cycle is currently 0.25 days. The company is concerned about the safety factor for the operation. Which of the following is the safety factor (α) of the current operation?

_____ is one in which employees at a given operation go to the source of required parts, such as machining or subassembly, and withdraw the units as they need them.