Question 1

The quality management tool called poka-yoke is not relevant to JIT systems.

Accepted Answer

A) True 
 B)False

Question 2

Which of the following is FALSE regarding the links between JIT and quality?

Accepted Answer

A)  Inventory hides bad quality; JIT immediately exposes it. 
B)  JIT reduces the number of potential sources of error by shrinking queues and lead times. 
C)  As quality improves, fewer inventory buffers are needed; in turn, JIT performs better. 
D)  If consistent quality exists, JIT allows firms to reduce all costs associated with inventory. 
E)  JIT increases the cost of obtaining good quality. 
A)  Inventory hides bad quality; JIT immediately exposes it. 
B)  JIT reduces the number of potential sources of error by shrinking queues and lead times. 
C)  As quality improves, fewer inventory buffers are needed; in turn, JIT performs better. 
D)  If consistent quality exists, JIT allows firms to reduce all costs associated with inventory. 
E)  JIT increases the cost of obtaining good quality.

Question 3

What are the 5Ss? Why does the list of the 5Ss sometimes have seven elements?

Accepted Answer

The five categories are sort/s

Question 4

Kanban is associated with all EXCEPT which of the following?

Accepted Answer

A)  small lot sizes 
B)  signals, such as cards, lights, or flags 
C)  moving inventory only as needed 
D)  increased material handling 
E)  reductions in inventory 
A)  small lot sizes 
B)  signals, such as cards, lights, or flags 
C)  moving inventory only as needed 
D)  increased material handling 
E)  reductions in inventory

Question 5

Product storage is an example of waste in the sense that no value is added.

Accepted Answer

A) True 
 B)False

Question 6

A product has annual demand of 1,000,000 units. The plant manager wants production to follow a two-hour cycle. Based on the following data, what setup time will enable the desired production cycle? d = 4000 units per day (250 days per year), p = 8000 units per day, H = $60 per unit per year, Q = 1000 (demand for two hours), and the hourly labor rate is $30.

Accepted Answer

A)  30 minutes 
B)  0.5 minutes 
C)  15 minutes 
D)  2.85 minutes 
E)  5.7 minutes 
A)  30 minutes 
B)  0.5 minutes 
C)  15 minutes 
D)  2.85 minutes 
E)  5.7 minutes

Question 7

Lead time for computers is 5 days with daily demand of 15 and safety stock of 5 computers. If management wants to use 10 kanbans how many computers should each one hold?

Accepted Answer

A)  25 
B)  1 
C)  8 
D)  10 
E)  13 
A)  25 
B)  1 
C)  8 
D)  10 
E)  13

Question 8

A manufacturer took the following actions to reduce inventory. Which of these is generally NOT accepted as a JIT action?

Accepted Answer

A)  It used a pull system to move inventory. 
B)  It produced in ever smaller lots. 
C)  It required deliveries directly to the point of use. 
D)  It picked the supplier that offered the lowest price based on quantity discounts. 
E)  It worked to reduce the company's in-transit inventory. 
A)  It used a pull system to move inventory. 
B)  It produced in ever smaller lots. 
C)  It required deliveries directly to the point of use. 
D)  It picked the supplier that offered the lowest price based on quantity discounts. 
E)  It worked to reduce the company's in-transit inventory.

Question 9

Weekly usage of a product is 8 units. Since the plant operates 50 weeks per year, this leads to annual usage of 400 units. Setup cost is $40 and annualized carrying cost is $80. Weekly production of this product is 12 units. Lead time is four weeks, and safety stock is one week's production. What is optimal kanban size? What is the optimal number of kanbans?

Accepted Answer

The answer of Weekly usage of a product is 8...

Question 10

U.S. managers often add two additional Ss to the Japanese 5S checklist, ________ and ________, that contribute to establishing and maintaining a Lean workplace.

Accepted Answer

safety, su

Question 11

Which of the following is specifically characterized by continuous and forced problem solving via a focus on throughput and reduced inventory?

Accepted Answer

A)  Just-in-time (JIT) 
B)  Toyota Production System (TPS) 
C)  Lean operations 
D)  Material requirements planning (MRP) 
E)  kanban 
A)  Just-in-time (JIT) 
B)  Toyota Production System (TPS) 
C)  Lean operations 
D)  Material requirements planning (MRP) 
E)  kanban

Question 12

Which of the following statements regarding a pull system is TRUE?

Accepted Answer

A)  Large lots are pulled from upstream stations. 
B)  Work is pulled to the downstream stations before it is actually needed. 
C)  Manufacturing cycle time is increased. 
D)  Problems become more obvious. 
E)  None of these is true of a pull system. 
A)  Large lots are pulled from upstream stations. 
B)  Work is pulled to the downstream stations before it is actually needed. 
C)  Manufacturing cycle time is increased. 
D)  Problems become more obvious. 
E)  None of these is true of a pull system.

Question 13

TPS stands for ________.

Accepted Answer

Toyota Pro

Question 14

Identify some of the signals that kanban systems use.

Accepted Answer

Kanban systems use a wide vari

Question 15

What are the underlying principles of Toyota's standard work practices?

Accepted Answer

Work is completely specified as to conte

Question 16

A kanban system requires that the process has little variability in lead time because shortages impact the entire production system.

Accepted Answer

A) True 
 B)False

Question 17

One goal of JIT partnerships is the reduction of setup cost by delivery in large lots directly to the using department as needed.

Accepted Answer

A) True 
 B)False

Question 18

A scheduler may find that freezing the portion of the schedule closest to the due dates allows the production system to function and the schedule to be met.

Accepted Answer

A) True 
 B)False

Question 19

JIT suppliers have concerns that the JIT firm's demands for small lot sizes are simply a way of transferring holding cost from the JIT firm to the suppliers.

Accepted Answer

A) True 
 B)False

Question 20

Which one of the following is a characteristic of a JIT partnership?

Accepted Answer

A)  third-party logistics never used 
B)  maximal product specifications imposed on supplier 
C)  active pursuit of vertical integration 
D)  removal of incoming inspection 
E)  frequent deliveries in large lot quantities 
A)  third-party logistics never used 
B)  maximal product specifications imposed on supplier 
C)  active pursuit of vertical integration 
D)  removal of incoming inspection 
E)  frequent deliveries in large lot quantities

Exam 15: Lean Operations

The quality management tool called poka-yoke is not relevant to JIT systems.

Which of the following is FALSE regarding the links between JIT and quality?

What are the 5Ss? Why does the list of the 5Ss sometimes have seven elements?

Kanban is associated with all EXCEPT which of the following?

Product storage is an example of waste in the sense that no value is added.

Lead time for computers is 5 days with daily demand of 15 and safety stock of 5 computers. If management wants to use 10 kanbans how many computers should each one hold?

A manufacturer took the following actions to reduce inventory. Which of these is generally NOT accepted as a JIT action?

U.S. managers often add two additional Ss to the Japanese 5S checklist, ________ and ________, that contribute to establishing and maintaining a Lean workplace.

Which of the following is specifically characterized by continuous and forced problem solving via a focus on throughput and reduced inventory?

Which of the following statements regarding a pull system is TRUE?

TPS stands for ________.

Identify some of the signals that kanban systems use.

What are the underlying principles of Toyota's standard work practices?

A kanban system requires that the process has little variability in lead time because shortages impact the entire production system.

One goal of JIT partnerships is the reduction of setup cost by delivery in large lots directly to the using department as needed.

A scheduler may find that freezing the portion of the schedule closest to the due dates allows the production system to function and the schedule to be met.

JIT suppliers have concerns that the JIT firm's demands for small lot sizes are simply a way of transferring holding cost from the JIT firm to the suppliers.

Which one of the following is a characteristic of a JIT partnership?

Operations and Productivity

Operations Strategy in a Global Environment

Project Management

Forecasting

Design of Goods and Services

Managing Quality

Process Strategies

Location Strategies

Human Resources, Job Design, and Work Measurement

Supply Chain Management

Inventory Management

Aggregate Planning and Sop

Material Requirements Planning Mrp and Erp

Short-Term Scheduling

Maintenance and Reliability

Decision-Making Tools

Linear Programming

Transportation Models

Waiting-Line Models

Learning Curves

Simulation

Applying Analytics to Big Data in Operations Management

Filters

U.S. managers often add two additional Ss to the Japanese 5S checklist, and , that contribute to establishing and maintaining a Lean workplace.