Exam 13: Lean Systems: Eliminating Waste Through the Supply Chain

A producer of molded plastic cases for a variety of MP3 players and PDAs needs to fulfill and order for 20500 units. There are currently 214 hours available, and 190 hours required for producing the order. The changeover time is .5 hours. Determine the minimum batch size if the producer is to use all extra capacity for changeovers.

Describe how various approaches to waste minimization contribute to the goal of matching production rate to demand.

A manufacturer of custom paint and finishing products has an order for 10,000 gallon cans of a particular sealer. The filling machine will require a total of 120 hours out of 151 hours available to fulfill this order. Cleaning the filling machine between production runs takes 1.2 hours. What is the minimum batch size for the order?

Facility-focused techniques

Workforce-focused waste reduction techniques include:

Those lean techniques that affect virtually all resources by their effects on the values of the business are described as:

Determine the appropriate number of kanbans for the following production scenario: Production time = .7 hours Transit time = .5 hours Wait time = 1.9 hours Demand per hour = 50 units Safety stock = 10% Container size = 20

Few businesses have succeeded without concentration efforts to eliminate nonvalue-adding steps in processes.

Small batch production

Kanban systems are best suited for manufacturing environments where there is great deal of customization and variability from one product to another.

Match these items. -Kanban

A technique that increases the flexibility in responding to market demand changes is

Match these items. -A capacity-focused waste reduction technique

One of the most significant benefits of reducing inventory comes from not having inventory to cover up problems.

Which of the following is not a waste reduction focus of lean systems?

Without ________, down stream work centers are directly dependent on upstream work centers.

Kanban utilizes ____ ______ of inventory between work centers, departments, and manufacturing plants.