Deck 7: Lean Thinking and Lean Systems

Question 1

Lean emphasizes all of the following except:

A)Setup time reductions
B)Cross training of workers
C)Lot size reduction
D)Increased utilization of machines

Answer 1

Increased utilization of machines

Question 2

External setup time refers to:

A)The time it takes workers to set up a machine during scheduled maintenance
B)The time to complete setup activities that do not require that the machine be stopped
C)The time it takes equipment vendors to set up the machine
D)None of the above

Answer 2

The time to complete setup activities that do not require that the machine be stopped

Question 3

The ideal setup time for a lean system is:

A)5 minutes
B)The time it takes the line to get ready
C)0 minutes
D)1 hour

Answer 3

0 minutes

Question 4

Reducing setup time is important because it:

A)Increases available capacity
B)Increases flexibility to meet schedule changes
C)Reduces inventory
D)All of the above

Question 5

With regards to suppliers,lean systems typically require:

A)Delivery of large lots at frequent intervals
B)Buyer inspection of goods and materials
C)Multiple sources from which to purchase
D)Long-term relationships and commitments

Question 6

One of the main objectives of a lean system is:

A)Striving for 'good enough'
B)Reduction of takt time
C)Reduction of waste
D)Define value from the manufacturer's perspective

Question 7

The time it takes a container to complete an entire circuit consists of:

A)Move time,time used,and wait time
B)Wait time,run time,setup time,and idle time
C)Fill time,wait time,move time,time used,and time to be returned to be filled again
D)None of the above

Question 8

If a work center has no empty kanban containers,the workers at the work center should do which of the following?

A)Continue to produce as much inventory as they can
B)Produce enough inventory to meet the following day's demand
C)Produce enough inventory to satisfy the master production schedule
D)Stop production

Question 9

Why is a uniform load desirable in a lean system?

A)To balance the workload on all work centers
B)To allow for production of safety stock
C)To signal the need for more parts
D)To increase the time for scheduled maintenance

Question 10

A kanban card is used to signal that:

A)The next work center is stopped
B)A materials handler has run out of parts
C)A machine has broken down
D)Parts are needed by the subsequent work center
E)A machine is ready for preventive maintenance

Question 11

If it takes 100 minutes to complete a circuit,demand at the next work center is 5 parts per minute,and a kanban container holds 20 parts,how many containers are required?

A)25
B)5
C)40
D)20

Question 12

Lean thinking can be applied to:

A)Manufacturing
B)Services
C)Functions other than operations
D)All of the above

Question 13

Reduction of setup time is accomplished by separating internal and external setups and:

A)Reducing inventory
B)Implementing a kanban system
C)Converting internal setup time to external setup time
D)Reducing lot sizes

Question 14

Managing quality in a lean system:

A)Is easy
B)Means that product and service defects are never defined as waste
C)Is done by suppliers
D)Requires continuously exposing and correcting quality problems

Question 15

Supplier management in a lean system:

A)May require co-location of supplier goods close to plants that receive delivery
B)Means and increase in the number of suppliers for each component
C)Generally involves short-term relationships with the buyer
D)Usually requires additional paperwork,as compared with the non-lean system

Question 16

Given the following information pertaining to item AX143,determine the appropriate number of kanban cards that should be used to support production. Demand rate = 500 units/week
Time for container to complete circuit = 2 weeks
Safety stock = 30 percent
Size of container = 5 units

A)<100 units
B)Between 100 and 500 units
C)>500 units
D)There is not enough information to answer the question

Question 17

Which of the following is NOT generally an element of a lean system?

A)Flexible workforce
B)Type II MRP system
C)Stable master schedule
D)Kanban pull system

Question 18

Which of the following is not an element of lean?

A)Small-lot sizes
B)Modularized master schedule
C)Multifunction workers
D)Kanban pull system
E)Perfect or nearly perfect quality

Question 19

The ideal lot size for a lean system is:

A)Infinite
B)One
C)The capacity of the machine
D)Variable according to the production requirements
E)None of the above

Question 20

For production control,lean pull systems are best suited for:

A)Repetitive manufacturing
B)Job shop production
C)Semi-repetitive batch manufacturing
D)Unpredictable demand

Question 21

With lean thinking,a firm's operations layout should evolve to a cellular manufacturing layout.

Question 22

Value stream maps are similar to flowcharts and are used for identifying the waste and non-value-added steps in the current process.

Question 23

Define the English terms in the 5S technique.How is this applied in practice?

Question 24

Lean is an example of a pull system while lean thinking is an example of a push system.

Question 25

A kanban system cannot be used in service industries.

Question 26

The Japanese term for waste is "gemba."

Question 27

According to the lean philosophy,a stable master production schedule is desirable to reduce the work-in-process inventories.

Question 28

One of the keys to reducing inventory is reducing lead-time.

Question 29

How is the 5 Whys technique used in a lean system?

Question 30

What are the five tenets of lean thinking? In your own words,provide a road map for implementing lean thinking in a manufacturing or service operations.

Question 31

Toyota Production System is another term for a lean system.

Question 32

Kaizen events typically take between 1 to 2 months.

Question 33

Takt time is the available time for production divided by demand.

Question 34

One-touch setups could require as long as 9 minutes to perform.

Question 35

Preventive maintenance is another term for stabilizing the master schedule.

Question 36

"Gemba" refers to data collection using the company's information system.

Question 37

External setups refer to actions that require stoppage of the production process.

Question 38

What are the seven forms of waste associated with a lean system?

Question 39

Explain the concept of value stream mapping.