Exam 21: Managing Operations

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Discuss principles of lean production, specifically the ways that the Toyota Production System uses to eliminate waste.

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Soichiro Toyoda advocates eliminating:
Defects: Because they are costly and because they have to be repaired or scrapped.
Overproduction: Because it must be stored and may never be sold.
Transportation costs: Because they can be minimised by locating close to suppliers and customers.
Waiting: Because idle resources are wasteful.
Inventory in excess of the minimum required: Because it is unproductive and costly.
Motion (whether by product, people, or machinery): Because it can be wasteful.
Processing (that is not productive): Because it is wasteful.

Match the term with its definition.Some terms may not be used a.Acceptance sampling b.Attributes c.Bottleneck d.Constraint e.Inspection f.ISO 9000 g.Operations h.Operations management i.Poka-Yoke j.Quality k.Total quality management l.Variables -The examination of a part or a product to determine whether it meets quality standards.

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e

For service firms, the customer has to arrive before production begins resulting in employee scheduling issues.

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Match the term with its definition.Some terms may not be used a.Continuous manufacturing b.Flexible manufacturing systems c.Job shops d.Lean production e.Make-or-buy decisions f.Operations g.Outsourcing h.Poka-yoke i.Project manufacturing j.Repetitive manufacturing k.Supply Chain Operations Reference model l.Synchronous manufacturing -Manufacturing operations used to create unique but similar products.

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Match the term with its definition.Some terms may not be used a.ABC method b.Associative forecasting c.Cooperative purchasing organisation d.Cycle counting e.Demand management strategies f.Economic order quantity g.Just-in-time inventory system h.Perpetual inventory system i.Physical inventory system j.Poka-yoke k.Statistical inventory control l.Two-bin inventory system -A method that provides for periodic counting of items in inventory.

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Ralph operates a computer-controlled machine.His jobs can be either large or small.To change the set-up from one product to another usually requires only a change in programming.This type of manufacturing is known as:

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Match the term with its definition.Some terms may not be used a.ABC method b.Associative forecasting c.Cooperative purchasing organisation d.Cycle counting e.Demand management strategies f.Economic order quantity g.Just-in-time inventory system h.Perpetual inventory system i.Physical inventory system j.Poka-yoke k.Statistical inventory control l.Two-bin inventory system -A method of controlling inventory that uses a targeted service level, allowing statistical determination of the appropriate amount of inventory to carry

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In March, chassis prep counts its inventory.In June, the cabinet shop does the same thing.In September, appliances count its inventory.This inventory system is known as:

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Match the term with its definition.Some terms may not be used a.Acceptance sampling b.Attributes c.Bottleneck d.Constraint e.Inspection f.ISO 9000 g.Operations h.Operations management i.Poka-Yoke j.Quality k.Total quality management l.Variables -The planning and control of a conversion process that includes turning inputs into outputs that customers desire.

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In order to achieve market success, a business merely needs to concentrate on either providing an excellent product or service, or devising an insightful marketing strategy.

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Bottlenecks in a process are responsible for slower throughput times for the entire process.

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Repetitive operations in manufacturing use:

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Weighing bags of mulch during a production process is an example of a variable inspection.

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The buying of products or services from a third party to manage a business's functions is known as:

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The quality of a finished product depends on the quality of the raw materials used to make it.

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Cooperative purchasing organisations for small businesses are more successful now because of the:

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Jasper operates a machine shop.Orders from his customers are small, but his machines can easily be set up to make other items for different customers.This type of manufacturing is known as:

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Match the term with its definition.Some terms may not be used a.Continuous manufacturing b.Flexible manufacturing systems c.Job shops d.Lean production e.Make-or-buy decisions f.Operations g.Outsourcing h.Poka-yoke i.Project manufacturing j.Repetitive manufacturing k.Supply Chain Operations Reference model l.Synchronous manufacturing -Manufacturing operations that usually involve computer-controlled equipment that can turn out products in smaller or more flexible quantities.

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Job shops in manufacturing use specialised equipment.

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The terms repetitive manufacturing and mass production are synonymous.

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