Deck 9: Lean Systems

Question 1

In lean, waste reduction should lead to?

A) Cost reduction
B) Value reduction
C) Value enhancement
D) Cost increases

Answer 1

C

Question 2

Toyota's quality control initiative was referred to initially as?

A) TQC
B) TQM
C) TQD
D) TQP

Answer 2

A

Question 3

All of the following are common pseudonyms for lean thinking except?

A) Lean systems
B) Lean manufacturing
C) Lean marketing
D) Lean production

Answer 3

C

Question 4

A common approach to waste reduction is?

A) Five-S
B) Five-P
C) Five-T
D) Five-Q

Question 5

Storage of too much raw material, WIP, and/or finished goods is which of the seven wastes?

A) Waiting
B) Transportation
C) Excess inventory
D) Excess movement

Question 6

Forming and refining effective work habits would be associated with which of the Five-S's?

A) Sort
B) Sweep
C) Self-discipline
D) Standardize

Question 7

Which of the following is not typically viewed as one of the Five-S's?

A) Sort
B) Sell
C) Set in order
D) Standardize

Question 8

All of the following are examples of the seven wastes except?

A) Overproducing
B) Excess quality
C) Waiting
D) Excess inventory

Question 9

Proper workplace cleaning and maintenance would be associated with which of the Five-S's?

A) Sort
B) Sweep
C) Self-discipline
D) Standardize

Question 10

Shigeo Shingo developed what concept that refers to error or mistake-proofing?

A) Kaizen
B) Kanban
C) Muda
D) Poka-yoke

Question 11

Waste refers to all of the following except?

A) Excess wait times
B) Excess revenues
C) Excess inventories
D) Excess material movements

Question 12

Much of the Toyota Production System was based on observation of which American car manufacturer?

A) General Motors
B) Chrysler
C) Ford
D) Chevrolet

Question 13

Excess inventories, scrap losses, rejects, and rework are examples of?

A) Waste
B) Buffers
C) Hedges
D) Stocks

Question 14

Excess idle machine or operator time is which of the seven wastes?

A) Waiting
B) Transportation
C) Excess inventory
D) Excess movement

Question 15

Toyota's quality control initiative was later renamed?

A) TQC
B) TQM
C) TQD
D) TQP

Question 16

The elimination of time spent searching for parts and tools would be associated with which of the Five-S's?

A) Sort
B) Sweep
C) Self-discipline
D) Standardize

Question 17

Reduction of processing variability would be associated with which of the Five-S's?

A) Sort
B) Sweep
C) Self-discipline
D) Standardize

Question 18

Lean thinking is best described as a(n)?

A) Way of life
B) Operating philosophy
C) Planning strategy
D) Supplier selection approach

Question 19

The most essential element in the use of lean systems is?

A) Inventory reduction
B) Variance magnification
C) Processing time reduction
D) Waste elimination

Question 20

In the Toyota Production System a material movement or production signal/card is referred to as a?

A) Poka-yoke
B) Kanban
C) Jidoka
D) Kaizen

Question 21

SMED was first developed and used at which car manufacturer?

A) Ford
B) Mercedes-Benz
C) Honda
D) Toyota

Question 22

Lean systems are also known as?

A) Push system
B) Shove system
C) Pull system
D) Yank system

Question 23

Which of the following is sometimes considered to be a sixth-S?

A) Scrap
B) Satisfaction
C) Self-awareness
D) Safety

Question 24

What is used to signal a need for items from an upstream manufacturing cell?

A) Jidoka
B) Andon
C) Kanban
D) Kaizen

Question 25

Consider a work center with a demand rate of 35 parts per hour and using a container that can hold 10 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 20 percent. What is the value of S for this system?

A) 35
B) 10
C) 1
D) 0.2

Question 26

Lean thinking with a firm's suppliers involves all of the following except?

A) Delivery of smaller quantities
B) More frequent deliveries
C) Earlier deliveries
D) Delivery to point of use

Question 27

A kanban that is used to authorize processing is referred to as?

A) Withdrawal kanban
B) Production kanban
C) Manufacturing kanban
D) Processing kanban

Question 28

All of the following are the steps for SMED (not necessarily in order) except?

A) Identify external setup tasks
B) Streamline internal and external elements
C) Convert internal setup activities to external setup activities
D) Eliminate external setup activities

Question 29

Consider a work center with a demand rate of 35 parts per hour and using a container that can hold 10 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 20 percent. What is the value of D (demand rate) for this system?

A) 35
B) 10
C) 1
D) 0.2

Question 30

Lean production tends to?

A) Rely on less frequent equipment setups than traditional layouts
B) Rely on more frequent equipment setups than traditional layouts
C) Rely on the same number of equipment setups than traditional layouts
D) Equipment setups are irrelevant in lean production

Question 31

Setups that are performed before a machine stops for changeover are referred to as?

A) Internal
B) External
C) Exterior
D) Interior

Question 32

Consider a work center with a demand rate of 35 parts per hour and using a container that can hold 10 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 20 percent. What is the value of C for this system?

A) 35
B) 10
C) 1
D) 0.2

Question 33

Lean layouts tend to?

A) Locate inventory more closely to the production floor than traditional layouts
B) Locate inventory further from the production floor than traditional layouts
C) Locate inventory in the same manner as a traditional layout
D) Inventory location is irrelevant in lean layouts

Question 34

Consider a work center with a demand rate of 35 parts per hour and using a container that can hold 10 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 20 percent. What is the value of T (time) for this system?

A) 35
B) 10
C) 1
D) 0.2

Question 35

The performance of quick equipment setups is often referred to as?

A) STED
B) SNED
C) SMED
D) SPED

Question 36

Consider a work center with a demand rate of 35 parts per hour and using a container that can hold 10 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 20 percent. What is the value of K for this system?

A) 3
B) 4
C) 5
D) 6

Question 37

A kanban that is used to authorize movement is referred to as?

A) Withdrawal kanban
B) Production kanban
C) Manufacturing kanban
D) Processing kanban

Question 38

Lean layouts tend to?

A) Use less visibility than traditional layouts
B) Use more visibility than traditional layouts
C) Use the same amount of visibility as traditional layouts
D) Visibility is irrelevant in lean layouts

Question 39

Consider a work center with a demand rate of 15 parts per hour and using a container that can hold 15 parts. It is estimated that the container takes 90 minutes to cycle through the work cell. Assume a safety stock level of 20 percent. What is the value of K for this system?

A) 1
B) 2
C) 3
D) 4

Question 40

Consider a work center with a demand rate of 35 parts per hour and using a container that can hold 10 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 20 percent. What is the maximum inventory level in this system?

A) 30
B) 40
C) 50
D) 60

Question 41

Consider a work center with a demand rate of 15 parts per hour and using a container that can hold 15 parts. It is estimated that the container takes 90 minutes to cycle through the work cell. Assume a safety stock level of 20 percent. What is the maximum inventory for this system?

A) 10
B) 20
C) 30
D) 40

Question 42

Keeping employees involved in the process of change is associated with which of the 6-E's of Lean?

A) Enlist
B) Enable
C) Engage
D) Encourage

Question 43

The following are part of the 6-E's of Lean except?

A) Enlist
B) Earnings
C) Excite
D) Encourage

Question 44

A significant roadblock to the implementation of lean practices in an organization can be the lack of a?

A) Lean momentum
B) Lean culture
C) Lean profitability
D) Lean cost-cutting

Question 45

Lean services focus on?

A) Customer needs
B) Shareholder returns
C) Profit
D) Supplier concerns

Question 46

Making transactions and other elements of processes known to users is referred to as?

A) Process awareness
B) Process control
C) Process visibility
D) Process monitoring

Question 47

After the 2011 earthquake and tsunami in Japan, Toyota experienced production level decreases of approximately?

A) 5%
B) 10%
C) 30%
D) Toyota did not experience production decreases

Question 48

Adopting lean practices can?

A) Result in reduced waste
B) Result in increased waste
C) Result in neither reduced nor increased waste
D) Lean practices are unrelated to waste

Question 49

Teaching employees to take actions to continually improve their processes is associated with which of the 6-E's of Lean?

A) Enlist
B) Enable
C) Engage
D) Encourage

Question 50

A Japanese term for continuous improvement is?

A) Andon
B) Jidoka
C) Kaizen
D) Blitz

Question 51

Workforces should be _________ to support lean production initiatives.

A) Forced
B) Coerced
C) Empowered
D) Not allowed

Question 52

Customer surveys should have all of the following characteristics except?

A) Long
B) Include open-ended questions
C) Designed to obtain truthful responses
D) Results should be shared with employees and customers

Question 53

A ________ group can be used to assess customer needs.

A) Target
B) Marketing
C) Family
D) Focus

Question 54

Encouraging employees to stay active in finding and correcting problems is associated with which of the 6-E's of Lean?

A) Empower
B) Excite
C) Engage
D) Encourage

Question 55

Inspiring employees to tap into their creative and innovative capabilities is associated with which of the 6-E's of Lean?

A) Empower
B) Excite
C) Engage
D) Encourage

Question 56

A focused (typically one-week) improvement effort is referred to as a kaizen ______.

A) Focus
B) Blitz
C) Crunch
D) Attack

Question 57

Hospital waste each year in the United States amounts to approximately?

A) 1 million pounds
B) 1.4 billion pounds
C) 2.4 billion pounds
D) 5 billion pounds

Question 58

To achieve a lean culture and to overcome bad habits, an organization should?

A) Practice
B) Procrastinate
C) Ignore the past
D) Resist change

Question 59

Seeking assistance and cooperation from all of the staff is associated with which of the 6-E's of Lean?

A) Enlist
B) Enable
C) Engage
D) Encourage

Question 60

Authorizing employees to make changes happen in the areas they control is associated with which of the 6-E's of Lean?

A) Empower
B) Excite
C) Engage
D) Encourage

Question 61

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of D for this system?

A) 5
B) 0.5
C) 0.1
D) 20

Question 62

Consider a work center with a demand rate of 50 parts per hour and using a container that can hold 12 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of S for this system?

A) 50
B) 12
C) 1
D) 0.1

Question 63

Technological changes have ________.

A) Made lean systems obsolete
B) Increased firms' movement away from lean
C) Slowed firms' movement away from lean
D) Provided new opportunities for lean systems

Question 64

If you calculate the number of containers needed in a Kanban system to be 3, how many containers should you use?

A) 3
B) 3.2
C) 4
D) Cannot be determined from the information given

Question 65

If you calculate the number of containers needed in a Kanban system to be 3.2, how many containers should you use?

A) 3
B) 3.2
C) 4
D) Cannot be determined from the information given

Question 66

The quality-based ISO certification is?

A) ISO 9000
B) ISO 10000
C) ISO 12000
D) ISO 14000

Question 67

Adding intelligence to lean is sometimes referred to as?

A) Smart push
B) Smart pull
C) Small push
D) Small pull

Question 68

Consider a work center with a demand rate of 50 parts per hour and using a container that can hold 12 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 10 percent. What is the maximum inventory level for this system?

A) 20
B) 40
C) 60
D) Cannot be determined from the information given

Question 69

Consider a work center with a demand rate of 50 parts per hour and using a container that can hold 12 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of K for this system?

A) 2
B) 4
C) 5
D) Cannot be determined from the information given

Question 70

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of T for this system?

A) 5
B) 0.5
C) 0.1
D) 20

Question 71

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of C for this system?

A) 5
B) 0.5
C) 0.1
D) 20

Question 72

Consider a work center with a demand rate of 50 parts per hour and using a container that can hold 12 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of D for this system?

A) 50
B) 12
C) 1
D) 0.1

Question 73

The textbook describes the use of lean systems in the field of?

A) Education
B) Construction engineering
C) Financial management
D) Architecture

Question 74

Consider a work center with a demand rate of 50 parts per hour and using a container that can hold 12 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of C for this system?

A) 50
B) 12
C) 1
D) 0.1

Question 75

Consider a work center with a demand rate of 50 parts per hour and using a container that can hold 12 parts. It is estimated that the container takes 1 hour to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of T for this system?

A) 50
B) 12
C) 1
D) 0.1

Question 76

A bank with no physical location is referred to as a(n)?

A) Direct bank
B) Indirect bank
C) Virtual bank
D) Hidden bank

Question 77

RFID (in a lean systems environment) can be used to?

A) Alert customers to price changes
B) Detect material consumption and remotely trigger replenishments
C) Signal the end of a production run
D) RFID is not typically used in a lean systems environment

Question 78

The environmental-based ISO certification is?

A) ISO 9000
B) ISO 10000
C) ISO 12000
D) ISO 14000

Question 79

Consider a work center with a demand rate of 20 parts per hour and using a container that can hold 5 parts. It is estimated that the container takes 30 minutes to cycle through the work cell. Assume a safety stock level of 10 percent. What is the value of S for this system?

A) 5
B) 0.5
C) 0.1
D) 20

Question 80

Offsetting carbon emissions from operations is referred to as being?

A) Carbon-positive
B) Carbon-negative
C) Carbon-constrained
D) Carbon-neutral