Exam 6: Lean Systems

Scenario 6.1 El Gran Raton, the producers of the finest carpincho wallets in all of Argentina, examined their production process in the form of a value stream map, displayed below. Daniel Penfield artist -With a batch size of 360 units, which process step in Scenario 6.1 is the bottleneck?

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Question 1

Correct Answer:

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Choose a simple, common process and create a value stream map containing the current state, plus a realistic future state, and implementation plan.

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Question 2

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Answers will vary. See the outline below for steps to be followed and information to be included.
VSM analysts begin by selecting a product family for which the mapping will be done. This is followed by drawing a current state map of the existing production situation, and gathering and including all pertinent information on material and information flows (cycle times, scrap rates, machine uptime, batch sizes, etc.). Once the current state map is completed, the analysts use lean systems principles (e.g., load leveling, pull scheduling, Kanban systems) to create a future state map with more streamlined product flows. In this step, sources of waste are highlighted, and means for eliminating them are identified. Finally an implementation plan for achieving the future state is developed, which then becomes the blueprint for implementing and fine tuning a lean system. The process does not stop here, but provides continuous improvement opportunities as a new future state map is drawn after the lean system has been further improved.

The value stream mapping tool often requires completion of the future state drawing before the current state drawing, to help managers see the future state goals and more easily identify problems with the current state of the process.

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Question 3

Correct Answer:

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False

Case 6.1 The Edward James Toy Company uses a Kanban system to make plastic wheels that are a component of several toys. The waiting time for a container of the wheels during production is 0.25 day; average processing time is 0.15 day per container. Each container holds 200 wheels. The company uses 2,000 wheels a day in the production of its products. -Use the information in Case 6.1. Using a policy variable of 5%, calculate the number of Kanban containers needed for the wheels.

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Question 4

Use of value stream mapping requires construction of a current state drawing, a future state drawing, and an implementation plan.

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Question 5

Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving.

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Question 6

In the Toyota Production System, all work must be completely specified as to , , and .

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Question 7

Which of the following actions would increase the number of containers in use in a Kanban system?

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Question 8

Lean systems maintain inventory in small lot sizes because small lot sizes:

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Question 9

A plant's manufacturing process has a takt time of 90 seconds per unit. This results in a process output of how many units per hour?

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Question 10

Champion Cooling Company uses a kanban system at their location in the Oklahoma City Metroplex. The daily demand for fans is 2,000 and management insists on using an alpha level of 0.1. They use containers that hold 20 items and takes 0.04 of a day to process. It takes 0.07 of a day to get a container filled and for it to wait during its cycle. How many containers should they use? If they use the nearest integer value number of containers, what is the actual system alpha?

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Question 11

Using customer demand to activate production of an item or service is called:

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Question 12

The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints, while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities.

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Question 13

An item sells at a rate of 600 units per day. If a plant works two shifts per day (480 minutes each shift), what takt time is required for the plant to meet this demand?

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Question 14

________ refers to mistake-proofing methods aimed at designing fail-safe systems that minimize human error.

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Question 15

List and briefly define the eight types of waste (or muda) that often occur in firms which must be eliminated in implementing lean systems.

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Question 16

With respect to lean systems, what is the advantage of standardized components?

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Question 17

Mistake-proofing is known by the term:

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Question 18

List and briefly define the 5S Practices that serve as an enabler and essential foundation of lean systems.

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Question 19

What are the supply chain implications of the lean system emphasis on close supplier ties?

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Question 20

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Exam 6: Lean Systems

Scenario 6.1 El Gran Raton, the producers of the finest carpincho wallets in all of Argentina, examined their production process in the form of a value stream map, displayed below. Daniel Penfield artist -With a batch size of 360 units, which process step in Scenario 6.1 is the bottleneck?

Choose a simple, common process and create a value stream map containing the current state, plus a realistic future state, and implementation plan.

The value stream mapping tool often requires completion of the future state drawing before the current state drawing, to help managers see the future state goals and more easily identify problems with the current state of the process.

Use of value stream mapping requires construction of a current state drawing, a future state drawing, and an implementation plan.

Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving.

In the Toyota Production System, all work must be completely specified as to ________, ________, ________ and ________.

Which of the following actions would increase the number of containers in use in a Kanban system?

Lean systems maintain inventory in small lot sizes because small lot sizes:

A plant's manufacturing process has a takt time of 90 seconds per unit. This results in a process output of how many units per hour?

Using customer demand to activate production of an item or service is called:

The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints, while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities.

An item sells at a rate of 600 units per day. If a plant works two shifts per day (480 minutes each shift), what takt time is required for the plant to meet this demand?

________ refers to mistake-proofing methods aimed at designing fail-safe systems that minimize human error.

List and briefly define the eight types of waste (or muda) that often occur in firms which must be eliminated in implementing lean systems.

With respect to lean systems, what is the advantage of standardized components?

Mistake-proofing is known by the term:

List and briefly define the 5S Practices that serve as an enabler and essential foundation of lean systems.

What are the supply chain implications of the lean system emphasis on close supplier ties?

Using Operations to Create Value

Process Strategy and Analysis

Quality and Performance

Capacity Planning

Constraint Management

Project Management

Forecasting

Inventory Management

Operations Planning and Scheduling

Resource Planning

Supply Chain Design

Supply Chain Logistic Networks

Supply Chain Integration

Supply Chain Sustainability

Supplement A Decision Making

Supplement J Operations Scheduling

Supplement K Layout

Supplement B Waiting Lines

Supplement C Special Inventory Models

Supplement D Linear Programming

Supplement E Simulation

Supplement F Financial Analysis

Supplement G Acceptance Sampling Plans

Supplement H Measuring Output Rates

Supplement I Learning Curve Analysis

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In the Toyota Production System, all work must be completely specified as to , , and .