Question 1

Define lean enterprise and the four principles of lean operating systems.

Accepted Answer

Lean enterprise refers to approaches tha

Question 2

Ford Motor Company has decided to switch to a pull system of manufacturing and distribution for its vehicles. Which one of the following is most likely to occur?

Accepted Answer

A) Inventory levels will increase. 
B) Component parts and subassemblies will be replenished only when needed. 
C) Dealer parking lot space will need to be increased. 
D) Finished goods inventory will decrease, but raw materials and work-in-process inventories will increase. 
A) Inventory levels will increase. 
B) Component parts and subassemblies will be replenished only when needed. 
C) Dealer parking lot space will need to be increased. 
D) Finished goods inventory will decrease, but raw materials and work-in-process inventories will increase.

Question 3

The number of Kanban cards is dependent on all of the following except

Accepted Answer

A) Average daily demand rate 
B) Setup time 
C) Part waiting time 
D) Safety stock 
A) Average daily demand rate 
B) Setup time 
C) Part waiting time 
D) Safety stock

Question 4

Lean production is focused on efficiency by reducing waste and improving process flow, while Six Sigma is focused on effectiveness by reducing errors and defects.

Accepted Answer

A) True 
 B)False

Question 5

Explain the concept of Single Minute Exchange of Die (SMED).

Accepted Answer

Long setup times waste manufacturing res

Question 6

Lean principles are of primary benefit to manufacturers and provide little value to service organizations.

Accepted Answer

A) True 
 B)False

Question 7

Compare and contrast a push system vs. a pull system.

Accepted Answer

Traditional factories use a push system,

Question 8

ABC Manufacturing 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 (round up)?

Accepted Answer

A) 5 sets 
B) 6 sets 
C) 7 sets 
D) 8 sets 
A) 5 sets 
B) 6 sets 
C) 7 sets 
D) 8 sets

Question 9

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 .25 days. The company is concerned with 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 .12 and there are still 2 containers, how many parts must each container now hold?

Accepted Answer

a. @#LAT-DLM& = [(KC - dp + w)] / dp + w) = [(2)(5

Question 10

Quick setup or changeover of tooling and fixtures is associated with ____.

Accepted Answer

A) Visual controls 
B) Single minute exchange of dies 
C) 5Ss 
D) Six Sigma 
A) Visual controls 
B) Single minute exchange of dies 
C) 5Ss 
D) Six Sigma

Question 11

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

Accepted Answer

A) True 
 B)False

Question 12

A manufacturer of automobile engines is designing a new Kanban system for engine #321. The demand for #321 is 75/day and they are built in groups of 8. The total process and wait time is 3 days. The manager wants an alpha ($\alpha$) of 2 or 200%. How many Kanbans are required?

Accepted Answer

K = Average daily demand during lead tim

Question 13

Total Production Maintenance (TPM)

Accepted Answer

A) Puts total responsibility on maintenance workers 
B) Puts total responsibility on equipment operators 
C) Eliminates all down time 
D) Employees preserve and protect their equipment 
A) Puts total responsibility on maintenance workers 
B) Puts total responsibility on equipment operators 
C) Eliminates all down time 
D) Employees preserve and protect their equipment

Question 14

Large batches often provide economies of scale and helps firms match inventory to market demand.

Accepted Answer

A) True 
 B)False

Question 15

Explain the 5Ss.

Accepted Answer

The 5Ss are derived from Japanese terms:

Question 16

Synchronization of the value chain is a lean approach to increasing speed and response.

Accepted Answer

A) True 
 B)False

Question 17

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

Accepted Answer

A) Maximum customer responsiveness 
B) Predefined schedule 
C) Finished goods inventory 
D) Based on forecast 
A) Maximum customer responsiveness 
B) Predefined schedule 
C) Finished goods inventory 
D) Based on forecast

Question 18

To accomplish single piece flow, a manufacturer needs the ability to change between products quickly and inexpensively.

Accepted Answer

A) True 
 B)False

Question 19

A withdrawal Kanban

Accepted Answer

A) Authorizes production 
B) Authorizes suppliers to produce 
C) Authorizes the transfer of an empty container 
D) Authorizes shipping to customers 
A) Authorizes production 
B) Authorizes suppliers to produce 
C) Authorizes the transfer of an empty container 
D) Authorizes shipping to customers

Question 20

Production Kanbans trigger the movement of parts.

Accepted Answer

A) True 
 B)False

Exam 17: Lean Operating Systems

Define lean enterprise and the four principles of lean operating systems.

Ford Motor Company has decided to switch to a pull system of manufacturing and distribution for its vehicles. Which one of the following is most likely to occur?

The number of Kanban cards is dependent on all of the following except

Lean production is focused on efficiency by reducing waste and improving process flow, while Six Sigma is focused on effectiveness by reducing errors and defects.

Explain the concept of Single Minute Exchange of Die (SMED).

Lean principles are of primary benefit to manufacturers and provide little value to service organizations.

Compare and contrast a push system vs. a pull system.

ABC Manufacturing 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 (round up)?

Quick setup or changeover of tooling and fixtures is associated with ____.

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

A manufacturer of automobile engines is designing a new Kanban system for engine #321. The demand for #321 is 75/day and they are built in groups of 8. The total process and wait time is 3 days. The manager wants an alpha ( α\alphaα ) of 2 or 200%. How many Kanbans are required?

Total Production Maintenance (TPM)

Large batches often provide economies of scale and helps firms match inventory to market demand.

Explain the 5Ss.

Synchronization of the value chain is a lean approach to increasing speed and response.

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

To accomplish single piece flow, a manufacturer needs the ability to change between products quickly and inexpensively.

A withdrawal Kanban

Production Kanbans trigger the movement of parts.

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

A manufacturer of automobile engines is designing a new Kanban system for engine #321. The demand for #321 is 75/day and they are built in groups of 8. The total process and wait time is 3 days. The manager wants an alpha ( $\alpha$ ) of 2 or 200%. How many Kanbans are required?