Deck 12: Lean Manufacturing

Question 1

Value stream mapping is a technique that aims to eliminate waste in a process.

Answer 1

True

Question 2

A focused factory network is a family of manufacturing facilities each producing components that are focused on a nearby large assembly facility.

Answer 2

False

Question 3

The goal of JIT production is to drive all inventory queues lower.

Answer 3

False

Question 4

Lean production is a management philosophy and a pull system throughout the plant.

Question 5

Lean production replaced JIT in the 1990s because JIT did not address the problem of reducing waste.

Question 6

In Japan we would expect a focused factory to be small and have only somewhere between 30 and 1,000 workers.

Question 7

Lean production is an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials,work in process and finished goods.

Question 8

Group technology is a philosophy wherein similar parts are grouped together and the processes required to make the parts are arranged as a work cell.

Question 9

Henry Ford used JIT concepts as he streamlined his moving assembly lines to make automobiles in the early 1900's.

Question 10

A principle of value stream mapping is to concentrate on speeding up value-added operations.

Question 11

"Quality at the source" requires factory workers to become their own inspectors.

Question 12

Group technology includes the set of psychological tests and training exercises given to group workers to insure a high level of teamwork.

Question 13

JIT production means that we produce the product before it is required so the customer does not wait for the product.

Question 14

Group technology cells help to eliminate movement and queue (waiting)time between operations.

Question 15

JIT manufacturing forces a firm to work with a lower water level despite safety hazards.

Question 16

In the textbook the expression "quality at the source" means that we need to purchase the best quality a supplier or vendor can provide.

Question 17

Uniform loading is where you schedule production with different amounts of the same product each day of the week to permit variation to meet changing demand requirements.

Question 18

Lean production requires a "push & pull" system of inventory replenishment.

Question 19

JIT is typically applied to non-repetitive manufacturing.

Question 20

A focused factory tends to be a small plant designed for one purpose.

Question 21

One of the many JIT techniques that have been successfully applied in service firms is the upgrading of housekeeping.

Question 22

One of the many JIT techniques that have been successfully applied in service firms is leveling facility load.

Question 23

The term "heijunka" means "misfit" in Japanese.In a manufacturing context it refers to highly variable demands on a manufacturing facility that lead to cycles of overtime and layoffs.

Question 24

One of the many JIT techniques that have been successfully applied in service firms is the eliminating of unnecessary activities.

Question 25

Firms in Japan tend to have short-term partnerships with their suppliers and customers.

Question 26

Uniform loading is a process of smoothing the production activity flow to dampen the reaction waves that normally occur in response to schedule variations.

Question 27

One of the many JIT techniques that have been successfully applied in service firms is the upgrading of quality.

Question 28

Company unions in Japan exist to foster a cooperative relationship with management.

Question 29

Kanban means "symbol" or "box" in Japanese.

Question 30

The term "freeze window" refers to the practice of building quality into the process and not identifying quality by inspection.

Question 31

One of the few JIT techniques that do not work well in service firms is demand-pull scheduling.

Question 32

Heijunka is a Japanese word that means to smooth the production flow.

Question 33

Preventive maintenance is emphasized in lean production to ensure the flows are not interrupted by downtime or malfunctioning equipment.

Question 34

Which of the following are related to lean production?

A)A philosophy of waste elimination
B)Lean consumption
C)Never running out of inventory
D)The Waehi-Subaru method
E)Full use of capacity

Question 35

Using the formula in the textbook the only parameters we need to determine the number of Kanban card sets is the average number of units demanded over some time period,the container size and the safety stock.

Question 36

"Kanban Squares" is an educational game played in Kanban training sessions.

Question 37

In Japanese manufacturing automation and robotics are used extensively to perform dull or routine jobs so employees are free to focus on important improvement tasks.

Question 38

A Kanban control system uses a signaling device to regulate JIT flows.

Question 39

Respect for people is a key to the Japanese improvement ideas in manufacturing.

Question 40

Subcontractor networks are not very important in Japanese manufacturing.

Question 41

Which of the following address elimination of waste under lean production?

A)Info-matic warehouse networks
B)Outsourced housekeeping
C)Quality at the source
D)Backflushing
E)Bottom-round management

Question 42

In trying to implement a lean production system you should work with suppliers to do which of the following?

A)Reduce lead times
B)Focus workstation capacities
C)Backflush
D)Provide quality at the source
E)Heijunka

Question 43

In implementing a lean production system you should work with suppliers to do which of the following?

A)Calculate lead times
B)Quality circles
C)Freeze windows
D)Make frequent deliveries
E)Achieve bottom-round management

Question 44

In the textbook Toyota's Fujio Cho identified which of the following types of waste to be eliminated?

A)Underproduction
B)Excess quality
C)Preventive maintenance
D)Product defects
E)Kaizen

Question 45

To implement a Kanban pull system the firm would do which of the following?

A)Reduce lot sizes
B)Force demand
C)Hire a consultant
D)Bottom-round management
E)Implement group technology

Question 46

Which one of the following concepts is not involved when implementing total quality control?

A)Workers being given responsibility
B)Enforce compliance
C)Fail-safe methods
D)Automatic inspection
E)Level schedule the factory

Question 47

In setting up a Kanban control system you need to determine the number of Kanban card sets needed.If the expected demand during lead time is 25 per hour,the safety stock is 20% of the demand during lead time,the container size is 5 and the lead time to replenish an order is 5 hours,what is the number of Kanban card sets needed?

A)5
B)20
C)27
D)30
E)34

Question 48

In designing a lean production facility layout a designer should do which of the following?

A)Design for work flow balance
B)Locate flexible workstations off line
C)Link operations through a push system
D)Balance capacity using job shop analysis
E)Always keep operations on a single floor of the factory

Question 49

In the textbook Toyota's Fujio Cho identified which of the following types of waste to be eliminated?

A)Excess quality
B)Overproduction
C)Underproduction
D)Environmental
E)Over-thinking

Question 50

In the textbook Toyota's Fujio Cho identified which of the following types of waste to be eliminated?

A)Heijunka
B)Motion
C)Excess capacity
D)Underproduction
E)Excess demand

Question 51

You have been called in as a consultant to set up a Kanban control system.The first thing to do is to determine the number of Kanban card sets needed.Your research shows that the expected demand during lead time for a particular component is 1,200 per hour.You estimate the safety stock should be set at 5% of the demand during lead time.The tote trays used as containers can hold 2 units of stock and the lead time to replenish an order is 10 hours.Which of the following is the number of Kanban card sets necessary to support this situation?

A)5,000
B)5,500
C)6,300
D)6,500
E)7,000

Question 52

Group technology (GT)is credited with which of the following benefits?

A)Reducing waiting time between process operations
B)Improving inventory discipline
C)Reducing required workforce skills
D)Improved labor relations
E)Improved small group functioning

Question 53

To implement a flow process in developing a lean system a firm might do which of the following?

A)Balance workstation capacities
B)Standardize product configurations
C)Process design with product design
D)Adopt a kaizen philosophy
E)Implement top-down management controls

Question 54

You have been called in as a consultant to set up a Kanban control system.The first thing to do is to determine the number of Kanban card sets needed.Your research shows that the expected demand during lead time for a particular component is 150 per hour.You estimate the safety stock should be set at 25% of the demand during lead time.The tote trays used as containers can hold 8 units of stock and the lead time it takes to replenish an order is 2 hours.Which of the following is the number of Kanban card sets necessary to support this situation?

A)42
B)47
C)68
D)89
E)94

Question 55

Which of the following statements holds true for Kanban production control systems?

A)The authority to produce or supply additional parts comes from upstream operations
B)In a paperless control system,containers can be used instead of cards
C)The cards or containers make up the Kanban push system
D)They require substantial quantitative analysis prior to implementation
E)They have not been successful outside of Japan and the United States

Question 56

Which of the following are elements that address elimination of waste under lean production?

A)Production ahead of demand
B)Group plant loading technology
C)Kanban production control system
D)Minimized run times
E)Full capacity utilization

Question 57

In setting up a Kanban control system you need to determine the number of Kanban card sets needed.If the expected demand during lead time is 50 per hour,the safety stock is 20% of the demand during lead time,the container size is 4.If the lead time to replenish an order is 8 hours,what number of Kanban card sets is needed?

A)60
B)80
C)90
D)120
E)150

Question 58

When implementing a lean production system a stabilized schedule is achieved using which of the following?

A)Level scheduling
B)Demand pull
C)Freeze window
D)Reduced lot sizes
E)Bottom-round management

Question 59

To implement a flow process in developing a lean system a firm might do which of the following?

A)Improve capacity utilization
B)Build product in anticipation of demand
C)Reduce setup/changeover time
D)Eliminate some fixed costs
E)Implement groupware

Question 60

Which of the following are key inventory reduction targets under lean production?

A)FIFO inventory
B)Hidden inventory
C)Safety stock
D)Lost inventory
E)Ladder inventory

Question 61

An activity involving periodic exploding of an end item's bill of materials to calculate how many of each part that go into the final product is called which of the following?

A)Frozen window
B)Backflushing
C)Level schedule
D)Group Technology
E)Kanban

Question 62

As lean production methods reduce change-over times and thus enable smaller economic lot sizes and less work-in-process inventory is the importance of quality increased or decreased? Why?

Question 63

What seven design principles guide the design of lean supply chains?

Question 64

Which of the following is a lean production technique that is not reported in the textbook to have been successfully applied in service firms?

A)Organize problem-solving groups
B)Upgrade housekeeping
C)Upgrade quality
D)Freeze windows
E)Eliminate unnecessary activities

Question 65

The Toyota Production System is predicated upon what two philosophies that are also central to the Japanese culture?

Question 66

Explain why lean manufacturing requires a stable demand environment.

Question 67

What are the five guidelines for implementing a lean supply chain presented by Womack and Jones,in their book Lean Thinking?

Question 68

Name Fujio Cho's seven prominent types of waste to be eliminated.

Question 69

Which of the following is a lean production technique that has been successfully applied in service firms?

A)Decision trees
B)Leveling the facility load
C)Linear programming
D)Fully utilizing capacity
E)Backflushing

Question 70

In a lean production system we expect to see which of the following?

A)No "just-in-case" extra inventory
B)More "just-in-case" extra inventory
C)More parts and fewer standardized product configurations
D)Managers being held responsible for quality of the work turned out
E)Closer management/labor relationships

Question 71

Imagine comparing a manufacturing operation using regular lot-sizing and the same operation with a Kanban/lean production approach.What would be your expectations of the difference between the total cost (i.e. ,inventory holding costs + setup/ordering costs)of each?

A)Inventory holding cost will increase non-linearly with inventory
B)Total costs will be lower for the regular lot-size operation
C)Total costs will be lower for the Kanban/lean production operation
D)The order quantity will be larger for the Kanban/lean production approach
E)As long as the total quantity is the same,total costs will be the same

Question 72

In setting up a kanban control system and you need to determine the number of kanban card sets needed.If the expected demand during lead time is 50 per hour,the safety stock is 20% of the demand during lead time,the container size is 4.If the lead time to replenish an order is 2 hours,what number of kanban card sets is needed?

Question 73

Uniform plant loading means smoothing the production flow to dampen schedule variation.This practice is also known by which Japanese name?

Question 74

In setting up a kanban control system you need to determine the number of kanban card sets needed.If the expected demand during lead time is 24 per hour,safety stock is 10% of the demand during lead time,the container size is 5.If the lead time to replenish an order is 5 hours,what number of kanban card sets is needed?