Exam 16: Lean Systems

A workstation must produce 400 units an hour.It takes 24 minutes to receive the necessary material for production from the previous workstation.Output is moved between workstations in containers holding 44 units.If the process uses a safety factor of 10%,then the amount of safety stock on average would be

Internal setup activities can be performed when a process is running.

Takt time is the pace at which production output is aligned with machine capacity.

Reducing variability in production through more accurate demand forecasts is one way to maintain uniform production levels.

Taiichi Ohno observed that customers in American supermarkets pull items through the system.

Firms that adopt lean production experience reductions in cycle time,inventory cost and employee training costs.

The output of a manufacturing cell is changed by adding or removing workers.

The concept of cellular layouts was developed by a U.S.engineer in the 1920s.

The pull system was developed by Ohno to coordinate production between processes.

The number of kanbans needed to maintain control in a pull system can be calculated from demand and lead time information.

All of the following are benefits expected from implementing lean production except

Manufacturing cells are comprised of similar machines to process a family of parts.

Advantages of small-lot production include requiring less space and lower capital investment.

What is a kanban and how is it used in a pull system?

The benefits of lean production include all of the following except reduced

The concept of pull production is easy to implement because it is similar to traditional scheduling procedures.

How many kanbans should circulate between two workstations if demand is 500 units per hour,lead time is 20 minutes,container sizes are 35,and the company uses a safety factor of 5%?

Producing items before they are needed is considered waste under the principles of lean production.

Kaizen is a Japanese term that means fool proofing to prevent defects.

The lower inventory levels associated with small-lot production make processes more dependent on each other.