Deck 17: Lean Operating Systems

Question 1

_____ is NOT a 5S principle that creates a well-organized work environment.

A) Stabilize
B) Standardize
C) Shine
D) Sustain

Answer 1

A

Question 2

Which of the following Ss of the 5Ss means to keep the process going through training, communication, and organizational structures?

A) Shine
B) Sort
C) Sustain
D) Standardize

Answer 2

C

Question 3

Which of the following Ss in the 5S system ensures that each item in a workplace is in its proper place or identified as unnecessary and removed?

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

Answer 3

A

Question 4

Principles of lean operating systems include all of the following EXCEPT _____.

A) eliminating waste
B) improving information technology
C) increasing speed and response
D) reducing costs

Question 5

Which of the following statements is TRUE of total productive maintenance (TPM)?

A) It puts total responsibility on maintenance workers.
B) It puts total responsibility on equipment operators.
C) Planned down time is maximized.
D) Employees preserve and protect their equipment.

Question 6

According to the Toyota Motor Company, which of the following is NOT one of the seven major waste categories?

A) Overproduction
B) Transportation
C) Motion
D) Single-piece flow

Question 7

In the 5Ss, a clean work area refers to _____.

A) sort
B) synchronize
C) shine
D) standardize

Question 8

According to the seven major categories of waste classified by Toyota Motor Company, long lead times and higher work-in-process are the results of _____.

A) overproduction
B) inventory
C) waiting time
D) transportation

Question 9

Which of the following is NOT a basic principle of a lean operating system?

A) Elimination of waste
B) Batching
C) Increased speed and response
D) Improved quality

Question 10

Timken Company illustrates the application of lean principles when it _____.

A) reduces the total cycle time for new product development
B) increases safety stock in its inventory system
C) expands factories and distribution centers
D) maximizes the number of parts or items in its systems

Question 11

Which of the following is NOT one of the 5Ss?

A) Set in order
B) Sort
C) Standardize
D) Single-piece flow

Question 12

Total productive maintenance (TPM) seeks to do all of the following EXCEPT _____.

A) maximizing equipment effectiveness
B) creating worker ownership of equipment by involving them in maintenance activities
C) fostering continuous improvement efforts
D) enabling multiple products in small batches to be run on the same equipment

Question 13

The process of producing large quantities of items as a group before they are transferred to the next operation is known as _____.

A) batching
B) outsourcing
C) reshoring
D) offshoring

Question 14

Which one of the following statements is TRUE of Lean Six Sigma?

A) Lean principles focus on advanced statistical methods.
B) It is difficult to use lean methods in nonmanufacturing environments.
C) It uses basic root cause, process, and data analysis techniques.
D) Six Sigma and lean principles are separate bodies of knowledge.

Question 15

Which of the following principles is NOT part of the 5Ss?

A) Synchronize
B) Set in order
C) Shine
D) Sustain

Question 16

Toyota classified waste into seven major categories. These categories include all of the following EXCEPT _____.

A) motion
B) ordering
C) inventory
D) waiting time

Question 17

Which one of the following is an example of waste in organizations?

A) High capacity resource utilization
B) Retraining and relearning time and expense
C) Correct factory routing of customer orders and jobs
D) High data integrity

Question 18

Southwest Airlines illustrates the application of lean principles when it _____.

A) reduces airplane turnaround time at airport gates
B) assigns airplane seats
C) serves all passengers in-flight dinners
D) charges a change of ticket fee for missing a scheduled flight

Question 19

Quality at the source requires _____.

A) starting with a plan
B) having reliable suppliers
C) doing it right the first time
D) having a good design

Question 20

A quick setup or changeover of tooling and fixtures is associated with _____.

A) visual controls
B) single minute exchange of dies
C) single-piece flow
D) six sigma

Question 21

The maximum authorized inventory for this part is _____.

A) less than 25 parts
B) more than 25 but less than or equal to 50 parts
C) more than 50 but less than or equal to 100 parts
D) more than 100 but less than or equal to 150 parts

Question 22

Which of the following is NOT a best practice and prerequisite for implementing a just-in-time system?

A) Maximizing the number of parts or items
B) Good calibration of all gauges and testing equipment
C) Clean and uncluttered workplaces
D) Minimizing setup/changeover time

Question 23

A withdraw Kanban authorizes _____.

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

Question 24

If the safety stock factor is changed to 0.1 and the number of parts per container is increased to 44, how many containers will be needed?

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

Question 25

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

A) Maximum responsiveness
B) Predefined schedule
C) Finished goods inventory
D) Forecast dependent

Question 26

The maximum authorized inventory for the problem given in #35 is _____.

A) less than or equal to 200 units
B) more than 200 but less than or equal to 300 units
C) more than 300 but less than or equal to 400 units
D) more than 400 units

Question 27

Which of the following ideas related to lean operating systems is FALSE?

A) The ideal order quantity for single piece flow is one.
B) Accidents are a form of waste in organizations.
C) A push system makes only what you can sell.
D) Overproduction is a form of waste in organizations.

Question 28

A(n) _____ produces finished-goods inventory in advance of customer demand using a forecast of sales.

A) single minute exchange of dies (SMED)
B) push system
C) Kanban
D) pull system

Question 29

Webster Manufacturing Inc. is implementing a Just-in-Time (JIT) system and wants to know how many Kanbans to use for the initial setup of its JIT system. The daily demand is 400 units and each Kanban (i.e., container) holds 15 units. The combined processing and waiting time per container is 0.7 days. If the initial alpha value for safety stock is 0.6, how many Kanban containers should be authorized?

A) More than 10 but less than or equal to 15 Kanbans
B) More than 15 but less than or equal to 20 Kanbans
C) More than 20 but less than or equal to 25 Kanbans
D) More than 25 Kanbans

Question 30

ABC Manufacturing Inc. 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? SEQ a,_b,_c, \* alphabetic \r 1a. 5 sets
SEQ a,_b,_c, \* alphabetic \nb. 6 sets
SEQ a,_b,_c, \* alphabetic \nc. 7 sets
SEQ a,_b,_c, \* alphabetic \nd. 8 sets

Question 31

Webster Manufacturing Inc. is implementing a Just-in-Time (JIT) system and wants to know how many Kanbans to use for the initial setup of its JIT system. The daily demand is 400 units and each Kanban (i.e., container) holds 15 units. The combined processing and waiting time per container is 0.7 days. If the initial alpha value for safety stock is 0.6, what is the maximum authorized inventory?

A) More than 100 but less than or equal to 200 units
B) More than 200 but less than or equal to 300 units
C) More than 300 but less than or equal to 400 units
D) More than 400 units

Question 32

If the number of containers is reduced to one, how many parts must it hold?

A) Less than 25 parts
B) More than 25 but less than or equal to 50 parts
C) More than 50 but less than or equal to 100 parts
D) More than 100 but less than or equal to 150 parts

Question 33

In a Kanban system, in the formula (i.e., K = [d (p + w)(1 + $\alpha$ )]/C), the alpha ( $\alpha$ ) is analogous to _____.

A) demand during the lead time
B) a form of safety stock
C) capacity utilization
D) the reorder point

Question 34

Which one of the following is a best practice of just-in-time systems?

A) Use of disposable containers
B) Increased setup/changeover times to maximize productivity
C) Minimal distance traveled for materials and parts handling systems
D) Highly specialized jobs with little or no cross-training

Question 35

Shine Motor Inc. has decided to switch to a "just-in-time system" of manufacturing and distribution for its vehicles. Which one of the following is most likely to occur?

A) Inventory levels will increase.
B) Component parts and subassemblies are now replenished only when needed.
C) Finished goods inventory will decrease, but raw materials and work-in-process inventories will increase.
D) The workers at any given process will produce units before they are needed.

Question 36

The number of Kanban cards is dependent on all of the following EXCEPT _____.

A) average daily demand rate
B) setup time
C) waiting time
D) safety stock

Question 37

A(n) _____ is a flag or a piece of paper that contains all relevant information for an order such as part number, description, process area used, time of delivery, quantity available, quantity delivered, and production quantity.

A) matrix
B) metric
C) gauge
D) Kanban

Question 38

A hinge manufacturing company employs a Kanban system for a component part. The daily demand is 900 hinges. Each container has a wait time of 0.05/day, and a processing time of 0.37 days. The container size is 60 hinges, and the safety factor (α) is 10%. Given this data, the number of Kanbans necessary for this system is _____.

A) less than 4 Kanbans
B) more than 4 but less than or equal to 8 Kanbans
C) more than 8 but less than or equal to 12 Kanbans
D) more than 12 but less than or equal to 16 Kanbans

Question 39

A manufacturing company is using a two container Kanban system between a downstream (using) and an upstream (producing) work center. Each container holds 25 parts. The using work center can handle 100 parts per day. The average elapsed time for the entire cycle is currently 0.4 days. The company is concerned about the efficiency (and safety stock policy) of the operation. The safety stock factor for the current operation is _____.

A) less than 0.20
B) more than 0.20 but less than or equal to 0.3
C) more than 0.3 but less than or equal to 0.4
D) more than 0.4 but less than or equal to 0.5

Question 40

Webster Manufacturing Inc. is implementing a Just-in-Time (JIT) system and wants to know how many Kanbans to use for the initial setup of its JIT system. The daily demand is 400 units and each Kanban (i.e., container) holds 15 units. The combined processing and waiting time per container is 0.7 days. If the initial alpha value for safety stock is 0.6 and the processing and waiting time is reduced by 30 percent due to job and process improvements, by how many units is the maximum authorized inventory reduced from the original Webster problem #23 and #24?

A) Less than 100 units
B) More than 100 but less than or equal to 200 units
C) More than 200 but less than or equal to 300 units
D) More than 300 but less than or equal to 400 units

Question 41

Large batches often reduce teardowns and setups and provide economies of scale.

Question 42

The 5Ss focus on improving waste generated by inefficient transportation.

Question 43

Lean operating systems seek to apply the principles of continuous flow to the production of discrete parts by reducing batch size, ideally to a size of one.

Question 44

Six Sigma addresses visible problems in processes; lean production is more concerned with less visible problems.

Question 45

Lean principles are always transferrable to front-office services that involve high customer contact and service encounters.

Question 46

According to the Toyota Motor Company, waiting time is necessary in production and is not classified as waste.

Question 47

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

Question 48

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

Question 49

Lean Six Sigma is simply the union of lean approaches with quality improvement techniques, each of which has been used independently in other applications.

Question 50

A clean and organized work area is an important principle of lean thinking.

Question 51

In the context of the 5Ss, standardize means to formalize procedures and practices to create consistency and ensure that
all steps are performed correctly.

Question 52

Knowledge bottlenecks and equipment breakdowns are a form of waste in organizations.

Question 53

When producing broad goods or service mix with diverse requirements on common equipment, the ideal strategy is to
run large batches.

Question 54

Total productive maintenance (TPM) strives to relieve machine operators of routine maintenance activities so that they can focus entirely on being productive.

Question 55

A goal of total productive maintenance is to have zero accidents in the entire life cycle of an operating system.

Question 56

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

Question 57

Single minute exchange of dies (SMED) frees up capacity for other productive uses.

Question 58

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.

Question 59

Lean enterprise refers to approaches that focus primarily on the elimination of waste throughout the value chain.

Question 60

The goal of total productive maintenance (TPM) is to minimize the costs associated with routine maintenance activities.

Question 61

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

Question 62

Explain the 5Ss.

Question 63

Nashua Corporation, a service organization, used lean principles and methods to reduce order-cycle time.

Question 64

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

Question 65

Production Kanbans trigger the movement of parts.

Question 66

Contrast batching with single-piece flow.

Question 67

Discuss the seven major categories of waste as defined by Toyota Motor Company.

Question 68

Lean principles are mostly beneficial to manufacturers and provide little value to service organizations.

Question 69

The number of Kanban cards is directly proportional to the amount of work-in-process inventory.

Question 70

In a push system, finished-goods inventory is produced in advance of customer demand using a forecast of sales.

Question 71

Starbucks successfully implemented lean principles.

Question 72

Explain the purpose of visual controls and give examples.

Question 73

Just-in-time (JIT) systems are based on the concept associated with pull systems rather than push systems.

Question 74

The Timken Company used a Lean Six Sigma approach that was highly successful.

Question 75

Which of the following statements is TRUE of the Community Medical Association (CMA) case study?

A) The case describes how the 5Ss were used by CMA's 50 databases.
B) Total savings was over $40 million from implementing an integrated operating system with a common data base compared to the previous system.
C) Doctors' total changeover and setup (i.e., system relog) time per patient increased after the new integrated operating system was implemented.
D) The quality of medical diagnosis and decisions (i.e., clinical quality) improved with the new system.

Question 76

Kanban is the Japanese term for elimination of waste.

Question 77

Compare and contrast a push system and a pull system.

Question 78

In a just-in-time (JIT) system, the computer inventory data is the interface and control point between customers and supply cycles.

Question 79

How does total productive maintenance (TPM) affect lean operating systems?

Question 80

Discuss the differences between lean production and Six Sigma.