Deck 21: Lean Systems

Question 1

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

Answer 1

True

Question 2

The time required for a worker to complete one pass through the operations assigned to her is called the operator cycle time.

Answer 2

True

Question 3

General purpose machines are an example of flexible resources.

Answer 3

True

Question 4

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

Question 5

A kanban square is a marked area designated for holding a set quantity of output.

Question 6

The individual generally credited with the development of lean production is an American.

Question 7

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

Question 8

Mass production means doing more with fewer workers,less inventory,and less space.

Question 9

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

Question 10

Push systems rely on predetermined production schedules often generated by computerized systems.

Question 11

In lean production,waste is defined as anything that does not add value to the product.

Question 12

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

Question 13

Kanbans are used to maintain the discipline required of a push production system.

Question 14

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

Question 15

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

Question 16

Kanbans were derived from the two-bin inventory system.

Question 17

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

Question 18

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

Question 19

Waiting for parts to arrive or for machines to finish production is considered a form of waste under the principles of mass production.

Question 20

Small-lot production reduces lead time but increases quality problems.

Question 21

One benefit of small-lot production is that workers show fewer tendencies to let poor quality pass.

Question 22

Setup time is not a component of the cumulative lead time for a manufactured product.

Question 23

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

Question 24

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

Question 25

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

Question 26

The authority for a worker to stop the production line when quality problems are encountered is known as poka-yoke.

Question 27

Poka-yoke is a Japanese term used to describe the removal of waste in a lean production system.

Question 28

A push system prevents both overproduction and underproduction.

Question 29

The lower inventory levels resulting from small-lot production hides problems in the production process.

Question 30

A poka-yoke is any foolproof device that prevents defects or injury from occurring.

Question 31

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

Question 32

One component of lead time,setup time,is often the biggest bottle neck.

Question 33

In lean production,a strong relationship exists between setup times and small lots.

Question 34

In a lean production system,kanban systems have been shown to handle large fluctuations in the production requirements on the final assembly line.

Question 35

Mixed-modelling sequencing is used at Toyota to reduce setup times.

Question 36

Flexible resources are a basic element of lean production.

Question 37

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

Question 38

In the dual kanban system,a withdrawal kanban authorizes the production of goods.

Question 39

Total productive maintenance combines preventive maintenance with kaizen.

Question 40

Lean concepts cannot be applied to services because services are intangible.

Question 41

All of the following factors pressure companies for quicker response and shorter cycle times except

A)demanding customers.
B)longer product life cycles.
C)globalization.
D)All the above are factors.

Question 42

Lower inventory levels make processes

A)less dependent on each other while keeping bottlenecks hidden.
B)less dependent on each other while revealing bottlenecks more quickly.
C)more dependent on each other while revealing bottlenecks more quickly.
D)more dependent on each other while keeping bottlenecks hidden.

Question 43

Which of the following is not a principle for reducing setup times?

A)converting external setup to internal setup
B)converting internal setup to external setup
C)separating internal setup from external setup
D)performing setup activities in parallel

Question 44

Which of the following statements concerning small-lot production is not true?

A)Small-lot production requires less space.
B)Small-lot production requires more capital investment.
C)Small-lot production simplifies transportation between workstations.
D)Small-lot production allows processes to be moved closer together.

Question 45

___ setups that can be performed in advance while the machine is running.

A)Internal
B)External
C)Parallel
D)Unnecessary

Question 46

Which of the following is not a basic element of lean production?

A)flexible resources
B)pull system
C)repetitive production
D)small lot production

Question 47

In a pull production system,a card that corresponds to a standard quantity of production is known as a(n)

A)jidoka.
B)andon.
C)kanban.
D)kaizen.

Question 48

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 number of kanbans that should be circulating between this workstation and the previous workstation is

A)2
B)4
C)6
D)8

Question 49

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

Question 50

In a pull system reducing the number of kanbans

A)increases inventory making problems more visible.
B)reduces inventory making problems less visible.
C)reduces inventory making problems more visible.
D)increases inventory making problems less visible.

Question 51

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%?

A)4
B)5
C)12
D)8

Question 52

A workstation's output is 200 bottles of wine per hour.It takes 45 minutes to receive a withdrawal kanban of corks from the previous workstation.The withdrawal kanban is attached to a container holding 30 corks.The process uses a safety factor of 20 percent.What is the number of withdrawal kanbans needed to support the bottling process?

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

Question 53

A workstation's output is 200 bottles of wine per hour.It takes 30 minutes to receive a withdrawal kanban of corks from the previous workstation.The withdrawal kanban is attached to a container holding 30 corks.The process uses a safety factor of 20 percent.What is the number of withdrawal kanbans needed to support the bottling process?

A)10
B)2
C)8
D)4

Question 54

Improved scheduling of materials,workers,and machines will most generally affect

A)processing time.
B)move time.
C)waiting time.
D)setup time.

Question 55

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

A)16
B)32
C)8
D)60

Question 56

In lean production,waste is defined as

A)overproduction.
B)high levels of inventory.
C)unnecessary movement.
D)All the above are waste.

Question 57

The pace at which production should take place to match the rate of customer demand is known as

A)product flow time.
B)jidoka time.
C)kanban time.
D)takt time.

Question 58

Which of the following is not a typical component of lead time?

A)processing time
B)maintenance time
C)waiting time
D)setup time

Question 59

Early adopters of lean production in North America were unsuccessful because they tried to implement lean by slashing inventories and forcing their suppliers to make more frequent deliveries.

Question 60

To keep machines running,firms can use either breakdown maintenance or preventative maintenance.

Question 61

The authority given to the worker to stop the production line if quality problems are encountered is known as

A)kaizen.
B)jidoka.
C)poka-yoke.
D)muda.

Question 62

What is a manufacturing cell and what is its purpose?

Question 63

Analyzing process flow and eliminating waste is referred to as

A)just-in-time.
B)the Toyota Production System.
C)value stream mapping.
D)total productive maintenance.

Question 64

The concept of allocating extra time to a schedule for planning,problem solving,and maintenance is known as

A)preventative scheduling.
B)preventive maintenance.
C)over capacity maintenance.
D)under capacity scheduling.

Question 65

Which of the following is not typically a component of lead time?

A)move time
B)breakdown time
C)wait time
D)setup time

Question 66

How does the pull system differ from the push system?

Question 67

Lean production is difficult to implement when

A)demand is highly variable.
B)product variety is high.
C)there are many unique products.
D)all of the above are true.

Question 68

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

Question 69

Which of the following is not a benefit of lean production?

A)greater flexibility
B)increased capacity
C)more customers
D)more product variety

Question 70

Mixed-model sequencing

A)facilitates total productive maintenance.
B)achieves uniform production levels.
C)increases product lead times.
D)reduces worker productivity.

Question 71

Combining the practice of preventive maintenance with the concepts of total quality is known as

A)total preventive quality.
B)total productive maintenance.
C)quality breakdown maintenance.
D)reliability assurance.

Question 72

Value stream mapping (VSM)is a tool for

A)reducing setup times.
B)improving quality at the source.
C)analyzing process flow.
D)designing manufacturing cells.

Question 73

A ___ is a foolproof device that prevents defects from occurring.

A)kaizen
B)jidoka
C)muda
D)poka-yoke

Question 74

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

A)inventory.
B)product variety.
C)pace requirements.
D)lead times.

Question 75

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

A)better quality.
B)shorter lead times.
C)reduced capacity.
D)improved sales.

Question 76

A ___ kanban is used to order material in advance of production.

A)material
B)supplier
C)production
D)withdrawal

Question 77

What role does the elimination of waste play in lean production?

Question 78

What are the benefits of small-lot production?