Question 1

The goal of total productive maintenance is to minimize the costs associated with routine maintenance activities.

Accepted Answer

A) True 
 B)False

Question 2

Kanban is a Japanese term for elimination of waste.

Accepted Answer

A) True 
 B)False

Question 3

Define a Kanban. Describe how it helps execute a pull system.

Accepted Answer

A Kanban is a flag or a piece of paper t

Question 4

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

Accepted Answer

A) True 
 B)False

Question 5

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

Accepted Answer

A) True 
 B)False

Question 6

Lean operating systems seek to apply the principles of continuous flow to the production of discrete parts by reducing batch size, ideally to a size of one.

Accepted Answer

A) True 
 B)False

Question 7

Lean enterprise refers to approaches that focus on the elimination of defects and errors throughout the value chain.

Accepted Answer

A) True 
 B)False

Question 8

Explain the purpose of visual controls and give examples.

Accepted Answer

Visual controls are indicators for opera

Question 9

A manufacturing company is using a two-container Kanban system between a downstream using) and an upstream producing) work center. Each container holds 25 parts. The using work center can handle 100 parts per day. The average elapsed time for the entire cycle is currently .40 days. The company is concerned about the efficiency of the operation.
a. What is the safety factor for the current operation?
b. What is the maximum authorized inventory for this part?
c. If the number of containers is reduced to one, how many parts must it hold?
d. If the efficiency is changed to .10 and the number of parts per container is increased to 44, how many containers will be needed?

Accepted Answer

a. @#LAT-DLM&= ([KC - dp + w)] / (dp + w) = [(2)(2

Question 10

Which of the following is least related to a pull system?

Accepted Answer

A) Building inventory 
B) Final assembly schedule 
C) Real time information 
D) Sales rate 
A) Building inventory 
B) Final assembly schedule 
C) Real time information 
D) Sales rate

Question 11

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

Accepted Answer

The Toyotas Motor Company classified was

Question 12

Which of the following is not one of the 5Ss?

Accepted Answer

A) Synchronize 
B) Standardize 
C) Shine 
D) Sustain 
A) Synchronize 
B) Standardize 
C) Shine 
D) Sustain

Question 13

Total Productive Maintenance TPM) strives to relieve machine operators of routine maintenance so that they can focus entirely on being productive.

Accepted Answer

A) True 
 B)False

Question 14

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

Accepted Answer

A) True 
 B)False

Question 15

Discuss the differences between lean production and Six Sigma.

Accepted Answer

Lean production addresses visible proble

Question 16

Which one of the following statements is true?

Accepted Answer

A) The heijunka system is a system of boxes much like in a mailroom set of boxes attached to a wall used to smooth production outputs. 
B) Producing goods early is a principle of lean. 
C) A university publication printed with 100% post-consumer recycled fiber is an example of total productive maintenance practice. 
D) Preventive maintenance is not a part of lean principles and practices. 
A) The heijunka system is a system of boxes much like in a mailroom set of boxes attached to a wall used to smooth production outputs. 
B) Producing goods early is a principle of lean. 
C) A university publication printed with 100% post-consumer recycled fiber is an example of total productive maintenance practice. 
D) Preventive maintenance is not a part of lean principles and practices.

Question 17

In a JIT system, the computer inventory data is the interface and control point between customers and supply cycles.

Accepted Answer

A) True 
 B)False

Question 18

A goal of total productive maintenance is to have zero accidents in the entire life cycle of the operating system.

Accepted Answer

A) True 
 B)False

Question 19

In a push system, finished goods inventory is produced in advance of customer demand using a forecast of sales.

Accepted Answer

A) True 
 B)False

Question 20

A company is using Kanban containers. There are two adjacent work centers, a downstream using) and an upstream producing) one. The using work center has a production rate of 200 parts per day and each container holds 20 parts. It takes .5 days for a container to make the entire cycle from the time it leaves the upstream center until it is returned, filled with production, and leaves again. The manager wants a safety factor $\alpha$) of 20%. The company is interested in reducing the number of containers.
a. What is the number of containers currently in use?
b. If the number of parts a container holds is increased to 24 parts, how many containers are needed?
c. If the company wants the number of containers holding 20 parts each) to be 5, what must the safety factor become?

Accepted Answer

a. K = (dp + w)(1 + @#LAT-DLM&)/C = [(200) .5) (1+

Exam 17: Lean Operating Systems

The goal of total productive maintenance is to minimize the costs associated with routine maintenance activities.

Kanban is a Japanese term for elimination of waste.

Define a Kanban. Describe how it helps execute a pull system.

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

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

Lean operating systems seek to apply the principles of continuous flow to the production of discrete parts by reducing batch size, ideally to a size of one.

Lean enterprise refers to approaches that focus on the elimination of defects and errors throughout the value chain.

Explain the purpose of visual controls and give examples.

Which of the following is least related to a pull system?

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

Which of the following is not one of the 5Ss?

Total Productive Maintenance TPM) strives to relieve machine operators of routine maintenance so that they can focus entirely on being productive.

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

Discuss the differences between lean production and Six Sigma.

Which one of the following statements is true?

In a JIT system, the computer inventory data is the interface and control point between customers and supply cycles.

A goal of total productive maintenance is to have zero accidents in the entire life cycle of the operating system.

In a push system, finished goods inventory is produced in advance of customer demand using a forecast of sales.

Goods, Services, and Operations Management

Value Chains

Measuring Performance in Operations

Operations Strategy

Technology and Operations Management

Goods and Service Design

Process Selection, Design, and Analysis

Facility and Work Design

Supply Chain Design

Capacity Management

Forecasting and Demand Planning

Managing Inventories

Resource Management

Operations Scheduling and Sequencing

Quality Management

Quality Control and Spc

Project Management

Work Measurement, Learning Curves, and Standards

Queuing Analysis

Modeling Using Linear Programming

Simulation

Work Measurement, Learning Curves, and Standards

Filters