Question 1

A takt time of 90 seconds generates a process output of:

Accepted Answer

A)  40 units per hour. 
B)  30 units per hour. 
C)  4 units per hour. 
D)  90 units per hour. 
A)  40 units per hour. 
B)  30 units per hour. 
C)  4 units per hour. 
D)  90 units per hour.

Question 2

Management at Pepman has decided to switch from a push system to a pull system of manufacturing. They are a large repetitive manufacturer of bicycles. Which one of the following is most likely to occur?

Accepted Answer

A)  The cycle time will increase, resulting in higher inventory levels. 
B)  The space required will increase due to the increase in the number of units that require rework. 
C)  The decrease in WIP inventory levels will reduce the space requirements. 
D)  The workers at any given process will produce units before they are needed by the subsequent process. 
A)  The cycle time will increase, resulting in higher inventory levels. 
B)  The space required will increase due to the increase in the number of units that require rework. 
C)  The decrease in WIP inventory levels will reduce the space requirements. 
D)  The workers at any given process will produce units before they are needed by the subsequent process.

Question 3

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:

Accepted Answer

A)  andon. 
B)  muda. 
C)  jidoka. 
D)  poka-yoke. 
A)  andon. 
B)  muda. 
C)  jidoka. 
D)  poka-yoke.

Question 4

________ practices include early testing of machine parts that may need to be replaced and making workers responsible for routine minor maintenance of their own equipment.

Accepted Answer

Total Prev

Question 5

One benefit of a lean system is that it reduces space requirements.

Accepted Answer

A) True 
 B)False

Question 6

What is the output for a process that has a takt time of 1.25 minutes per unit?

Accepted Answer

60 minutes per hour

Question 7

The Japanese term for continuous improvement in quality and productivity is ________.

Accepted Answer

The answer of The Japanese term for continuous improvement in...

Question 8

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called ________.

Accepted Answer

The answer of Automatically stopping the process when something is...

Question 9

Continuous improvement with lean systems:

Accepted Answer

A)  involves navigating a ship over treacherous rocks. 
B)  requires periodically increasing lot sizes or workforce levels to uncover problems. 
C)  entails systematically stressing the system and focusing on problem areas. 
D)  focuses exclusively on internal operations without addressing relationships with customers and suppliers. 
A)  involves navigating a ship over treacherous rocks. 
B)  requires periodically increasing lot sizes or workforce levels to uncover problems. 
C)  entails systematically stressing the system and focusing on problem areas. 
D)  focuses exclusively on internal operations without addressing relationships with customers and suppliers.

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 24 items and takes 0.02 of a day to process. It takes 0.08 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?

Accepted Answer

k = @#LAT-DLM& = @#LAT-DLM& = 9.16 → 9 containers

Question 11

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
-Use the data in Scenario 6.1 to calculate the per unit processing time for Process A if El Gran Raton decides to run a batch size of 360 units. The per unit time is:

Accepted Answer

A)  310 seconds. 
B)  46.67 seconds. 
C)  340 seconds. 
D)  696.67 seconds. 
A)  310 seconds. 
B)  46.67 seconds. 
C)  340 seconds. 
D)  696.67 seconds.

Question 12

With a batch size of 300 units, what is the per unit processing time for Process C?

Accepted Answer

A)  5 minutes 12 seconds 
B)  5 minutes 48 seconds 
C)  6 minutes 
D)  5 minutes 30 seconds 
A)  5 minutes 12 seconds 
B)  5 minutes 48 seconds 
C)  6 minutes 
D)  5 minutes 30 seconds

Question 13

Just-in-time (JIT) systems rely on inspectors to inspect quality into the product.

Accepted Answer

A) True 
 B)False

Question 14

The takt time of a process is defined as:

Accepted Answer

A)  the cycle time needed to match the rate of production to the rate of consumption. 
B)  the total time required to move an item through a process. 
C)  the time required to change a machine to run a new model. 
D)  the lead time necessary to notify maintenance that a problem has occurred in an operation. 
A)  the cycle time needed to match the rate of production to the rate of consumption. 
B)  the total time required to move an item through a process. 
C)  the time required to change a machine to run a new model. 
D)  the lead time necessary to notify maintenance that a problem has occurred in an operation.

Question 15

What is group technology and what advantages are accrued from its use?

Accepted Answer

The theory is to group parts or products

Question 16

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

Accepted Answer

A) True 
 B)False

Question 17

"When in doubt, weed it out" describes which 5S element?

Accepted Answer

A)  Sort 
B)  Straighten 
C)  Shine 
D)  Standardize 
A)  Sort 
B)  Straighten 
C)  Shine 
D)  Standardize

Question 18

Combining parts or products with similar characteristics into families and setting machines aside for their production is known as:

Accepted Answer

A)  the one-worker, multiple machines (OWMM) method of production. 
B)  the standardized component method of manufacturing. 
C)  group technology. 
D)  the flexible workforce approach to manufacturing. 
A)  the one-worker, multiple machines (OWMM) method of production. 
B)  the standardized component method of manufacturing. 
C)  group technology. 
D)  the flexible workforce approach to manufacturing.

Question 19

What did the production manager say to the pile of scrapped material?

Accepted Answer

A)  "Hello muda." 
B)  "Hello fadduh." 
C)  "We need more kanbans." 
D)  "JIT II Brute?" 
A)  "Hello muda." 
B)  "Hello fadduh." 
C)  "We need more kanbans." 
D)  "JIT II Brute?"

Question 20

In the Toyota Production System, services and goods are pushed to the next available person or machine to maintain smooth, rapid flow.

Accepted Answer

A) True 
 B)False

Exam 6: Lean Systems

A takt time of 90 seconds generates a process output of:

Management at Pepman has decided to switch from a push system to a pull system of manufacturing. They are a large repetitive manufacturer of bicycles. Which one of the following is most likely to occur?

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:

________ practices include early testing of machine parts that may need to be replaced and making workers responsible for routine minor maintenance of their own equipment.

One benefit of a lean system is that it reduces space requirements.

What is the output for a process that has a takt time of 1.25 minutes per unit?

The Japanese term for continuous improvement in quality and productivity is ________.

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called ________.

Continuous improvement with lean systems:

With a batch size of 300 units, what is the per unit processing time for Process C?

Just-in-time (JIT) systems rely on inspectors to inspect quality into the product.

The takt time of a process is defined as:

What is group technology and what advantages are accrued from its use?

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

"When in doubt, weed it out" describes which 5S element?

Combining parts or products with similar characteristics into families and setting machines aside for their production is known as:

What did the production manager say to the pile of scrapped material?

In the Toyota Production System, services and goods are pushed to the next available person or machine to maintain smooth, rapid flow.

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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