Deck 7: Lean Systems

Question 1

Preventive maintenance is typically given very low priority in just-in-time systems.

Answer 1

False

Question 2

Just-in-time (JIT)systems inspect quality in the product.

Answer 2

False

Question 3

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

Answer 3

True

Question 4

Lean systems are operating systems that are designed to create efficient processes by taking a total systems perspective.

Question 5

The "Made for You" system implemented in McDonald's restaurants since 2000 shifts the company more closely to a push method of production.

Question 6

A just-in-time (JIT)system is the organization of resources,information flows,and decision rules that can enable an organization to realize the benefits of the JIT philosophy.

Question 7

Just-in-time (JIT)systems need close relationships with suppliers.

Question 8

The pull method is when the production of an item begins in advance of customer needs.

Question 9

For firms along the supply chain,two aspects of lean systems that are important to manage include close supplier ties and small batches.

Question 10

Underproduction is a type of waste that often occurs in firms.

Question 11

The goal of single-digit setup is to have a setup completed in less than 10 hours.

Question 12

Lowering inventory levels in a manufacturing process typically has the effect of masking production problems such as capacity imbalances,excessive scrap and unreliable suppliers.

Question 13

JIT systems maintain relatively large lot sizes as a means to reduce process variability.

Question 14

Value-added activities are those tasks that transform the product or service in some measurable way.

Question 15

The just-in-time (JIT)philosophy is the belief that wastes can be eliminated by cutting inventory and removing non-value-added activities in operations.

Question 16

The push method of production is a method in which customer demand activates production of an item.

Question 17

Just-in-time (JIT)systems prefer that production is done is large lot sizes.

Question 18

The goal of single-digit setup means having setup times shorter than 10 seconds.

Question 19

A kanban is a card used to control the flow of production in many just-in-time systems.

Question 20

To lower process variability,standardized components is a preferred characteristic of JIT systems.

Question 21

A JIT II system brings the supplier into the customer's plant.

Question 22

The number of kanban cards limits the amount of inventory in the manufacturing system.

Question 23

Hidden problems are generally uncovered during the process of reducing inventory.

Question 24

One benefit of a just-in-time system is that it reduces equipment utilization.

Question 25

One goal of JIT partnerships is the elimination of in-plant inventory,in the form of raw materials,parts,or components; failure to meet this goal is a sign that suppliers are undependable.

Question 26

If any employee senses that the process is producing defects or is about to go out of proper specification, He or she has the responsibility to stop the process.This is called jidoka.

Question 27

One benefit of a just-in-time system is that it reduces space requirements.

Question 28

The rewards system normally needs to be revamped when a just-in-time (JIT)system is implemented.

Question 29

Because of the concept of employee involvement,workers in a JIT environment have flexibility to use the individual work methods that they prefer.

Question 30

Since the service organizations have limited use of inventory,JIT concepts are a relevant.

Question 31

One method that JIT systems use to implement the process of continuous improvement is to remove kanban cards from the system.

Question 32

JIT suppliers have concerns that the JIT firm's demands for small lot sizes are simply a way of transferring holding cost from manufacturer firm to the supplier firm.

Question 33

Lean systems are not appropriate for service operations.

Question 34

Just-in-time systems do not need stable master production schedules.

Question 35

As a consequence of the high quality processes of JIT,close supplier partnerships are unnecessary.

Question 36

One benefit of a just-in-time system is that it reduces space requirements.

Question 37

In the JIT facility,the next person who uses or further processes and item or information is referred to as the immediate customer.

Question 38

Reducing distance is a common JIT goal,both inside and outside facilities.Outside,it manifests itself in attempts to get suppliers closer to facilities; inside,it is a common layout tactic.

Question 39

One benefit of a just-in-time system is that it reduces lead time.

Question 40

Kanban cards are required for a just-in-time system.

Question 41

The just-in-time (JIT)philosophy is about

A) reducing cost by reducing the number of suppliers.
B) a comprehensive approach to eliminate waste.
C) improving quality by selecting certified suppliers.
D) improving delivery performance by doing all operations ahead of time.

Question 42

There are many requirements for the successful implementation of the JIT system of production.Which one of the following is not such a requirement of the JIT system?

A) uniform assembly schedule
B) short setup time
C) low machine failure and low defects
D) substantial natural resources

Question 43

Use of value stream mapping requires construction of a current state drawing,a future state drawing,and an implementation plan.

Question 44

The just-in-time (JIT)system is a(n)

A) management system of people and procedures to fulfill all delivery deadlines.
B) production system of small-lot manufacturing to reduce work-in-process inventory.
C) materials management system for removing all inventories.
D) integrated system of managing resources, information, and decision processes to eliminate waste.

Question 45

If infrequent,large shipments of purchased items are arranged with suppliers,large inventory savings for these items can be realized.

Question 46

A value stream map shows the flows of materials and information and the lines of responsibility and authority.

Question 47

Production to customized individual orders are very well suited to lean systems.

Question 48

The quality management tool called poka-yoke is not relevant to JIT systems.

Question 49

Stable master production schedules are not needed for lean systems.

Question 50

The JIT concept will not work without the proper environment.Which one of the following characteristics is most common to firms that have successfully implemented a JIT system?

A) uniform assembly schedules
B) specialized workforce
C) high rates of machine failures
D) longer setup times

Question 51

A JIT II system brings the supplier into the customer's plant.

Question 52

Because most services cannot be inventoried,there is little place for JIT to help service organizations achieve competitive advantage.

Question 53

All of the following wastes but one often occur in the firms.

A) Defects
B) Overutilization of employees
C) Motion
D) Overproduction

Question 54

The reward and benefits systems in place in companies need not be reviewed with the implementation of a lean system.

Question 55

Setup time is irrelevant when using lean systems.

Question 56

The just-in-time production system is a total system concept that takes cultural environment,managerial practice,and support of the workforce into account.Which one of the following statements regarding the basic philosophy of JIT systems is TRUE?

A) Sufficient amounts of natural resources are the main element for the successful implementation of JIT systems.
B) For managers, a high level of inventory is regarded as the main resource that they can utilize for flawless operation of the manufacturing system.
C) The JIT system eliminates buildup of inventories by coordinating the flow of materials between processes.
D) One of the few disadvantages of a JIT system is the large storage area requirement for inventory.

Question 57

With implementation of lean systems,activities such as scheduling,expediting,and improving productivity become part of the duties of lower-level personnel.

Question 58

Superior features and volume flexibility are the most emphasized features in lean systems.

Question 59

Cross-training is a common JIT tactic to improve flexibility.

Question 60

One benefit of a lean system is that it increases equipment utilization.

Question 61

When a push system is replaced by a pull system using small lot sizes,which one of the following is expected to happen?

A) WIP will increase.
B) Cycle time will decrease.
C) More units will be reworked to fix a quality problem.
D) More space will be required for inventory.

Question 62

In a JIT II system the

A) in-plant representative replaces the buyer, salesperson, and sometimes the materials planner.
B) customer need not have close interaction with the supplier.
C) customer is brought into the plant as an active member of the purchasing department of the supplier.
D) sales effort of the supplier increases but the cost of materials to the customer decreases.

Question 63

The final assembly schedule in a JIT system

A) should be developed for each product independent of the process requirements for the other products.
B) strives to create a uniform flow at the work centers in the plant.
C) avoids the use of small lot sizes because they create many production orders and cause confusion.
D) allow daily changes in demand levels, regardless of size, to be incorporated immediately into the work center schedules.

Question 64

Which one of the following competitive priorities is most often emphasized in JIT production?

A) high-performance design
B) volume flexibility
C) product flexibility
D) low cost

Question 65

Which of the following statements about using JIT systems for services is FALSE?

A) Reservation systems can be used to provide uniform facility loads.
B) Unlike manufacturing, there is little need for analyzing work methods because services are typically customized.
C) The need to develop a flexible workforce is a function of the degree of customization of the services provided.
D) Preventive maintenance can be important for a service.

Question 66

Which one of the following is an advantage of just-in-time (JIT)systems?

A) JIT systems reduce equipment needs by using larger lot sizes.
B) JIT systems can be implemented in any production environment.
C) JIT systems result in a decrease in safety stock and work-in-process inventory.
D) JIT systems result in an increase in manufacturing lead times.

Question 67

Continuous improvement with JIT systems

A) involves navigating a ship over treacherous rocks.
B) requires periodically increasing lot sizes or workforce levels to uncover problems.
C) entails systematically stressing the system and focusing on problem areas.
D) focuses exclusively on internal operations because relationships with customers and suppliers are addressed by the logistics department.

Question 68

Early shipments to a company utilizing a JIT system result in

A) stockouts for the company.
B) back orders for the company.
C) extra inventory for the company.
D) decreased production costs for the company.

Question 69

Which of the following is not an example of the pull method of material flows?

A) replenishing inventory in a retail outlet based on forecast demand
B) selecting the toppings for a pizza based on specific customer orders
C) a flooring contractor that only stocks samples of products, ordering supplies from manufacturers once customers place orders
D) Dell Computers make-to-order system for fulfilling orders placed through its on-line retailing site

Question 70

Companies utilizing JIT systems generally have

A) many suppliers to assure that material shortages never occur.
B) suppliers that are located nearby to decrease delivery lead time.
C) suppliers that are willing to accept short-term contracts.
D) suppliers who are low-cost producers.

Question 71

The advantages of JIT systems include all but which one of the following?

A) reduction in space requirements
B) increase in productivity
C) reduction in inventory
D) reduction in machine utilization

Question 72

Of the following statements,which one is most characteristic of a JIT system of production?

A) high variability in the daily loads for individual workstations
B) high conformance to product or service quality specifications
C) large lot sizes to achieve uniform operating system workloads
D) high dependence on customized components, as in high variability in components

Question 73

A kanban system is an important mechanism for JIT management.Which one of the following statements regarding the operation of a kanban system is TRUE?

A) A typical kanban used in the JIT system includes various information such as item number, unit price, competitor's product name, and its price.
B) A kanban can be used to set the order quantity, but not the inventory level.
C) A kanban and a container move as a pair once production begins at the fabrication process.
D) An empty container can be exchanged for a full container at the storage location even though no kanban is on the full container.

Question 74

JIT systems utilize the standardization of components because standardization

A) decreases the demand for each component.
B) increases worker productivity.
C) allows for small lot sizes more easily.
D) decreases repeatability.

Question 75

Companies have adopted various slogans to describe initiatives to develop lean systems.Which one of the following slogans would not be consistent with the philosophy of lean systems?

A) stockless production
B) synchronous manufacturing
C) hidden inventory
D) material as needed

Question 76

A supplier to a company using JIT II

A) will incur increased invoicing and payment costs but will get higher prices.
B) will be able to sell directly to the engineering department of the customer.
C) must be very flexible to incur the dramatic swings in requirements from the customer.
D) enjoys a savings in personnel costs because the in-plant representative is employed by the customer.

Question 77

Which one of the following statements is TRUE?

A) Two operating rules for the kanban system are (1) the container size should be equal to at least seven days of supply and (2) each container must have a kanban card.
B) The kanban system is more effective when the assembly schedule calls for small lots and does not fluctuate much from day to day.
C) The number of kanban cards should be equal to the desired safety stock times alpha.
D) Supplier performance is much more important in U.S. environments than such factors as lot sizes, scrap losses, and worker flexibility.

Question 78

JIT systems maintain inventory in small lot sizes because small lot sizes

A) increase pipeline inventory, allowing the organization to buffer against demand uncertainties.
B) increase the quality level of the product.
C) enable schedules to utilize machine capacities more efficiently.
D) increase manufacturing lead time because of the increase in waiting time.

Question 79

Which one of the following is not one of the characteristics of JIT systems?

A) pull method of material flows
B) consistently high conformance quality
C) large batch sizes to provide a cushion of inventory
D) close supplier ties

Question 80

In JIT systems,if a defective product is found,which of the following is generally NOT done?

A) The production line is stopped.
B) The defective unit is passed on to the next workstation.
C) The defective unit is returned to the worker responsible for creating the defect.
D) The production line is made aware of the problem without stopping the line.