Exam 6: Lean Systems

Explain the meaning of the term takt time, and use a numerical example to illustrate.

A plant's manufacturing process has a takt time of 72 seconds per unit. This results in a process output of how many units per hour?

When determining the number of kanban containers, discuss the impact of alpha, the policy variable, on the total amount of inventory in the system. If alpha is set equal to zero, is system inventory zero? What would be required to achieve a system-wide inventory of zero?

The Peeps factory can be described as a three step process consisting of Mixing, Forming, and Packaging. Peeps are made in batches of 1,000 and have a daily demand of 75,000 units during what the plant manager likes to call "the Peep season." Mixing has a cycle time of .02 seconds with a setup time of 30 seconds; Forming has a setup time of 24 seconds and a cycle time of .03 seconds, and Packaging has a setup time of 15 seconds with a cycle time of .04 seconds. Each process step is handled by one operator, who is available for 8 hours a day. What is the process bottleneck if each process step is assumed to have 100% uptime?

While lean systems work very well for manufacturing systems, they cannot be applied to service systems.

If the inventory advantages of a lean system are to be realized, ________ lot sizes must be used.

All improvements to the Toyota Production System must be made using the ________ method.

The list of five S practices includes ________, ________, ________, ________ and ________.

In lean systems, work-in-process inventory is a direct result of overproduction and waiting.

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 -Scenario 6.1 shows a value stream map with the picture separated into a top and bottom halves, each encircled by a dashed line. The bottom half of the picture could best be described as representing the:

One big advantage of lean systems is that they can usually be put in place without any major changes to existing layouts.

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

A ________ assembly line produces a mix of models in smaller lots.

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 value stream map to conduct a complete analysis of the carpincho wallet production process. Calculate all raw material and WIP lead times and determine overall process capacity assuming El Gran Raton uses a batch size of 300 units. If a single carpincho wallet were ordered today, how long before it would reach the back pocket of the delighted customer if his order is but one of an average of 2,230 orders (all for a single wallet) during an average 5 day work week. *Assume that the days indicated on the lead time ladder are based on a different batch size and not applicable to the 300 unit batch currently in use.*

Explain how a line-flow strategy can be used to reduce or eliminate setups.

What is schedule stability and why is it important in a lean system?

Items to be assembled that fit together only the proper way are an example of:

________ is the philosophy that waste can be eliminated by cutting unnecessary inventory and removing non-value-adding activities in operations.

Some Kanban systems are set up without Kanban cards, and use the material containers or open spaces in a work area to withdraw materials.

An item is used in Process B at a rate of 150 units per day. Process A works one shift per day (480 minutes) and supplies Process B's requirements. What takt time is required in Process A to meet Process B's demand?