Exam 17: Lean Operating Systems

A company is using a Kanban system with 2 containers, each holding 50 parts, between a downstream (using) and an upstream (producing) work center. The using work center can handle 250 jobs per day. The average elapsed time for the entire cycle is currently 0.25 days. The company is concerned about the safety factor for the operation and the size of the containers. a.What is the efficiency rating of the current operation? b.If the company decides to use only one container, how many parts must it hold? c.If the safety factor is changed to 0.12 and there are still 2 containers, how many parts must each container now hold?

Total productive maintenance (TPM) seeks to do all of the following EXCEPT _____.

A quick setup or changeover of tooling and fixtures is associated with _____.

Which of the following ideas related to lean operating systems is FALSE?

Shine Motor Inc. has decided to switch to a "just-in-time system" of manufacturing and distribution for its vehicles. Which one of the following is most likely to occur?

Which one of the following statements is TRUE of Lean Six Sigma?

Discuss the seven major categories of waste as defined by Toyota Motor Company.

Which of the following statements is TRUE of the Community Medical Association (CMA) case study?

A hinge manufacturing company employs a Kanban system for a component part. The daily demand is 900 hinges. Each container has a wait time of 0.05/day, and a processing time of 0.37 days. The container size is 60 hinges, and the safety factor (α) is 10%. Given this data, the number of Kanbans necessary for this system is _____.

Single minute exchange of dies (SMED) frees up capacity for other productive uses.

Webster Manufacturing Inc. is implementing a Just-in-Time (JIT) system and wants to know how many Kanbans to use for the initial setup of its JIT system. The daily demand is 400 units and each Kanban (i.e., container) holds 15 units. The combined processing and waiting time per container is 0.7 days. If the initial alpha value for safety stock is 0.6 and the processing and waiting time is reduced by 30 percent due to job and process improvements, by how many units is the maximum authorized inventory reduced from the original Webster problem #23 and #24?

Six Sigma addresses visible problems in processes; lean production is more concerned with less visible problems.

When producing broad goods or service mix with diverse requirements on common equipment, the ideal strategy is to run large batches.

Explain the 5Ss.

Contrast batching with single-piece flow.

Which one of the following is a best practice of just-in-time systems?

Explain the purpose of visual controls and give examples.

ABC Manufacturing Inc. uses a Kanban system for a component. The daily demand is 800 units. Each container has a combined waiting and processing time of 0.34 days. If the container size is 50 and efficiency (safety) factor is 9 percent, how many Kanban card sets should be authorized?

In lean thinking, waste need not be classified as simply material waste such as scrap and defective parts.

Lean Six Sigma is simply the union of lean approaches with quality improvement techniques, each of which has been used independently in other applications.