Question 1

What is the difference between the "push" and "pull" methods of material flow? Which method does lean systems use?

Accepted Answer

With the pull method, customer demand (a

Question 2

Regarding the Eight Types of Waste that must be eliminated to implement lean systems, using expensive high precision equipment when a simpler machine would suffice is part of which general waste category?

Accepted Answer

A)  Motion 
B)  Overproduction 
C)  Inappropriate Processing 
D)  Defects 
A)  Motion 
B)  Overproduction 
C)  Inappropriate Processing 
D)  Defects

Question 3

Heijunka is the leveling of production load by both volume and product mix.

Accepted Answer

A) True 
 B)False

Question 4

A ________ is based on both a withdrawal card and a production-order card, to control inventory quantities more closely.

Accepted Answer

two-card K

Question 5

The lean system concept will not work without the proper environment. Which one of the following characteristics is most common to firms that have successfully implemented a lean system?

Accepted Answer

A)  uniform assembly schedules 
B)  specialized workforce 
C)  high rates of machine failures 
D)  longer setup times 
A)  uniform assembly schedules 
B)  specialized workforce 
C)  high rates of machine failures 
D)  longer setup times

Question 6

In the Toyota Production System, when a work station needs more material, it is obvious to both the worker and the supplier that material is needed. Further, the amount needed must be understood as well as the delivery time for replenishment.

Accepted Answer

A) True 
 B)False

Question 7

JIT II refers to a form of supplier partnership that places a supplier representative, who is empowered to plan and schedule the replenishment of materials from the supplier, in the customer's plant on a full-time basis.

Accepted Answer

A) True 
 B)False

Question 8

Regarding the Eight Types of Waste that must be eliminated to implement lean systems, manufacturing an item before it is needed is part of which general waste category?

Accepted Answer

A)  Inappropriate Processing 
B)  Waiting 
C)  Inventory 
D)  Overproduction 
A)  Inappropriate Processing 
B)  Waiting 
C)  Inventory 
D)  Overproduction

Question 9

Transforming a current process design to one embodying a ________ philosophy is a constant challenge for management, often fraught with implementation issues.

Accepted Answer

The answer of Transforming a current process design to one...

Question 10

Burdell Salad Dressings uses a Kanban system. The daily demand for corrugated boxes used in packaging its dressings is 300 boxes. The average waiting time for a container of boxes is 0.25 day. The processing time for a container of boxes is 0.1 day, and a container holds 10 boxes. If Burdell wishes to use a 5% policy variable, what is the level of work in process inventory in their plant?

Accepted Answer

k = @#LAT-DLM& = @#LAT-DLM& = 11.025 → 12 containe

Question 11

Lean systems use the standardization of components because standardization:

Accepted Answer

A)  decreases the demand for each component. 
B)  increases repeatability. 
C)  increases lot sizes more easily. 
D)  decreases repeatability. 
A)  decreases the demand for each component. 
B)  increases repeatability. 
C)  increases lot sizes more easily. 
D)  decreases repeatability.

Question 12

In lean systems, if a defective product is found, which of the following is generally not done?

Accepted Answer

A)  The production line is stopped. 
B)  The defective unit is passed on to the next workstation. 
C)  The defective unit is returned to the worker responsible for creating the defect. 
D)  The production line is made aware of the problem without necessarily stopping the line. 
A)  The production line is stopped. 
B)  The defective unit is passed on to the next workstation. 
C)  The defective unit is returned to the worker responsible for creating the defect. 
D)  The production line is made aware of the problem without necessarily stopping the line.

Question 13

What are the supply chain implications of the lean system emphasis on small lot sizes?

Accepted Answer

Small lot sizes reduce average inventory

Question 14

Champion Cooling Company uses a kanban system at their two locations in the Oklahoma City Metroplex. The daily demand for fans is 2,000 at each location and management insists on using the same alpha level (0.1) at both locations. Location Reno uses containers that hold 20 items and takes 0.04 of a day to process a container. It takes 0.07 of a day to get a container filled and for it to wait during its cycle. Location Western uses containers that hold 24 items and takes 0.02 of a day to process a container. It takes 0.08 of a day to get a container filled and for it to wait during its cycle. Which location has the higher level of inventory? Assume that both locations round up to the next highest integer number of containers.

Accepted Answer

kReno = @#LAT-DLM& = @#LAT-DLM& = 12.1 → 12
WIPRen

Question 15

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
-In Scenario 6.1, what does the triangle between Process A and Process B represent?

Accepted Answer

A)  WIP 
B)  takt 
C)  OWMM 
D)  kanban 
A)  WIP 
B)  takt 
C)  OWMM 
D)  kanban

Question 16

In a ________ system based on other Kanban signals, an empty space signals a need to fill it.

Accepted Answer

The answer of In a ________ system based on other...

Question 17

Which one of the following statements regarding the Toyota production system is best?

Accepted Answer

A)  It is particularly well suited for making irregularly used parts and customized "specials." 
B)  It is a "push system," with orders pushed out in anticipation of future requirements. 
C)  Each container has either a withdrawal or production-ordering Kanban. 
D)  It does not use poka yoke or 5S practices. 
A)  It is particularly well suited for making irregularly used parts and customized "specials." 
B)  It is a "push system," with orders pushed out in anticipation of future requirements. 
C)  Each container has either a withdrawal or production-ordering Kanban. 
D)  It does not use poka yoke or 5S practices.

Question 18

A method in which production of an item begins in advance of customer needs is called:

Accepted Answer

A)  the andon method. 
B)  the pull method. 
C)  the jidoka method. 
D)  the push method. 
A)  the andon method. 
B)  the pull method. 
C)  the jidoka method. 
D)  the push method.

Question 19

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

Accepted Answer

A) True 
 B)False

Question 20

Which one of the following is an advantage of lean systems?

Accepted Answer

A)  Lean systems reduce equipment needs by using larger lot sizes. 
B)  Lean systems can be implemented in any production environment. 
C)  Lean systems result in a decrease in safety stock and work-in-process inventory. 
D)  Lean systems result in an increase in manufacturing lead times. 
A)  Lean systems reduce equipment needs by using larger lot sizes. 
B)  Lean systems can be implemented in any production environment. 
C)  Lean systems result in a decrease in safety stock and work-in-process inventory. 
D)  Lean systems result in an increase in manufacturing lead times.

Exam 6: Lean Systems

What is the difference between the "push" and "pull" methods of material flow? Which method does lean systems use?

Regarding the Eight Types of Waste that must be eliminated to implement lean systems, using expensive high precision equipment when a simpler machine would suffice is part of which general waste category?

Heijunka is the leveling of production load by both volume and product mix.

A ________ is based on both a withdrawal card and a production-order card, to control inventory quantities more closely.

The lean system concept will not work without the proper environment. Which one of the following characteristics is most common to firms that have successfully implemented a lean system?

In the Toyota Production System, when a work station needs more material, it is obvious to both the worker and the supplier that material is needed. Further, the amount needed must be understood as well as the delivery time for replenishment.

JIT II refers to a form of supplier partnership that places a supplier representative, who is empowered to plan and schedule the replenishment of materials from the supplier, in the customer's plant on a full-time basis.

Regarding the Eight Types of Waste that must be eliminated to implement lean systems, manufacturing an item before it is needed is part of which general waste category?

Transforming a current process design to one embodying a ________ philosophy is a constant challenge for management, often fraught with implementation issues.

Lean systems use the standardization of components because standardization:

In lean systems, if a defective product is found, which of the following is generally not done?

What are the supply chain implications of the lean system emphasis on small lot sizes?

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 -In Scenario 6.1, what does the triangle between Process A and Process B represent?

In a ________ system based on other Kanban signals, an empty space signals a need to fill it.

Which one of the following statements regarding the Toyota production system is best?

A method in which production of an item begins in advance of customer needs is called:

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

Which one of the following is an advantage of lean systems?

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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