Question 1

Which of the following dual-card Kanban rules are not correct?
1)One Kanban per container
2)The more Kanban cards are in the system, the more smoothly manufacturing operates
3)Standardized Containers and loads
4)In some cases, parts can be made without a production Kanban

Accepted Answer

The correct answers are (2) and (4). The statement that more Kanban cards in the system lead to smoother manufacturing is incorrect; in fact, more cards can lead to overproduction and inefficiency. Also, parts should not be made without a production Kanban, as this goes against the principles of Kanban for controlling inventory and production.

Question 2

Choose, among the following statements, the ones which correctly describe the inner workings of a basic Kanban production system.
1)A Kanban card is attached to every 10th container of items that has been produced
2)A Kanban card is an easily understood, virtual signal
3)Kanban is the Japanese word for container
4)The Kanban card stays with the container until the contents are used once attached

Accepted Answer

The Kanban card is a key component of the Kanban system, acting as a signal for the movement, production, or supply of items in a manufacturing or production process. It typically stays with its associated container until the items within are used, facilitating a visual management system that helps ensure a smooth flow of materials and work.

Question 3

Depending on who you ask, you will get different answers regarding how to distinguish a pull system from a push system depending.Choose the likely bases for distinguishing a pull system from a push system depending.
1)Information flow
2)Order release
3)Shop floor WIP levels
4)Lot size

Accepted Answer

A pull system is characterized by information flow from downstream to upstream, indicating when and how much to produce. This distinguishes it from a push system, where information flows from upstream to downstream, and production is based on forecasts and predetermined schedules. The order release is also important as pull systems only release orders when there is demand, while push systems release orders based on a predetermined schedule. The level of work-in-progress inventory on the shop floor is another factor, as push systems tend to have high levels of inventory while pull systems aim for minimal inventory. Lot size is not necessarily a defining characteristic of either system as both can use various lot sizes.

Question 4

Among the following relative disadvantage claims for a pull manufacturing, which one is most likely to be true?

Accepted Answer

Pull manufacturing relies on demand to trigger the release of production, which may lead to idling of workers during periods of low demand. This is in contrast to push manufacturing, where production is pushed to match a certain level of supply regardless of demand, which can utilize workers more consistently. The other three options are potential advantages of pull manufacturing.

Question 5

Mom &Pop Inc.uses 6 kanban cards for a system with a container size of 500 units.Using the demand information bellow, find the safety stock level.The estimated lead time is 1 day.
$$\begin{array} { c | c c c c c c } 
\text { Daily } & 1 & 2 & 3 & 4 & 5 & 6 \
\hline \text { Demand } & 1,000 & 500 & 3,000 & 4,000 & 3,000 & 500
\end{array}$$

Accepted Answer

The safety stock level is calculated as the difference between the maximum daily demand and the daily production quantity covered by one kanban card. The maximum daily demand is 4,000 units. With 6 kanban cards and a container size of 500 units, the system covers 3,000 units daily (6 cards * 500 units per card). Therefore, the safety stock level is 4,000 units (max demand) - 3,000 units (covered by kanban) = 1,000 units.

Question 6

A company implemented a computerized Kanban system that required a considerable amount of asset investment.However, the performance enhancement was not as much as expected.Which of the following correctly explains the reason for this phenomenon?

Accepted Answer

The answer of A company implemented a computerized Kanban system...

Question 7

The dual Kanban system uses more than one type of Kanban cards.Choose the correct type of Kanban cards for a dual Kanban system
1)Withdrawal Kanban
2)Inventory Kanban
3)Supermarket deposit Kanban
4)Transportation Kanban

Accepted Answer

The dual Kanban system typically uses two types of Kanban cards: Withdrawal Kanban and Production Kanban. The Withdrawal Kanban signals the need to move materials from a supply area to the production area, while the Production Kanban signals the need to produce more items.

Question 8

Among the following relative advantage claims for a pull manufacturing, which ones are likely to be true?
1)The system operates with almost no WIP inventory
2)Less maintenance is required
3)There is not much need to forecast demands
4)Only when it is needed, value is added to incomplete product

Accepted Answer

The answer of Among the following relative advantage claims for...

Question 9

With a push system, it is more likely that defects will pass through to the next process without being detected.Choose among the following, the likely consequences of this situation.
1)Increase in rework costs
2)Increase in customer returns
3)Increase in asset utilization
4)Increase in overall throughput

Accepted Answer

A push system means that products are being pushed through the production process without any consideration for demand or capacity constraints. This increases the likelihood of defects passing through to the next process without being detected, leading to an increase in rework costs. Additionally, these defects may also lead to an increase in customer returns, hence Option B is correct. Option C and D are incorrect as they suggest an increase in asset utilization and overall throughput, which may not necessarily be true as defects may lead to a decrease in efficiency and productivity.

Question 10

Which of the following descriptions are not correct for a push system?
1)There is no clear visibility between processes
2)The workers on shop floor lack the autonomy to stop the manufacturing on their own initiative
3)Production is only initiated when the down- stream process initiates its own activity
4)The WIP inventory levels are high at most locations

Accepted Answer

In a push system, production is based on forecasted demand, not initiated by downstream activity, making (3) incorrect for a push system.

Question 11

John is tasked with purchasing some new containers to use in the company's Kanban system.While he has most of the Kanban system configuration information, he cannot find the container size information.Find the container size using the Kanban system configuration information.
The average demand during lead time is 1025 units and the safety stock level is set to 19 units.There are currently 8 Kanban cards in the system.Find the closet size.

Accepted Answer

First, we need to calculate the reorder point which is the sum of average demand during lead time and safety stock level: 1025 + 19 = 1044 units. 
Next, we need to calculate the container size which is the reorder point divided by the number of Kanban cards: 1044/8 = 130.5 units. 
Since we cannot have half a container, we round up to the nearest whole number and the closest option is choice B with a container size of 130 units.

Question 12

Which of the following statements do not correctly describe pull manufacturing?
1)Material flow is determined by the need of the downstream workstation
2)Control is transferred from the beginning of the line to the end
3)A single piece flow is ideal for a push system and not for a pull system
4)Tries to minimize the number of items pulled at the same time

Accepted Answer

Statement 3 is incorrect because a single piece flow is actually ideal for a pull system, not a push system. Pull systems aim to produce only what is needed by the next process in the production line, which aligns with the concept of single piece flow, where items are produced and moved through the process one at a time.

Question 13

Susan is tasked with purchasing some new containers to use in the company's Kanban system.While she has most of the Kanban system configuration information, she cannot find the container size information.Find the container size using the Kanban system configuration information.
The average daily demand is 2050 units and lead time is 3 days.The safety stock level is set to 200 units.There are currently 10 Kanban cards in the system.Find the closest size.

Accepted Answer

The answer of Susan is tasked with purchasing some new...

Question 14

For Panama.Inc., there have been having problems with deciding on the number of Kanban cards in the system.There were several material shortages during the last period.In order to prevent shortages while maintaining an efficient Kanban system, how many Kanban cards should be released in the system?
The lead time is 2 day and the safety stock level is set to 15% of the average demand during the day.The container size is 10 units per container.The following is the demands over the last 10 days.
$$\begin{array} { c | r r r r r r r r r r } 
\text { Days } & 1 & 2 & 3 & 4 & 5 & 6 & 7 & 8 & 9 & 10 \
\hline \begin{array} { c } 
\text { Daily } \
\text { demands }
\end{array} & 100 & 98 & 97 & 120 & 123 & 125 & 121 & 100 & 110 & 105
\end{array}$$

Accepted Answer

First, we need to calculate the average daily demand:

Average Demand = (100+98+97+120+123+125+121+100+110+105)/10 = 110.9

Next, we need to calculate the safety stock level:

Safety Stock Level = 15% * 110.9 = 16.64 ≈ 17 units

Then, we need to calculate the reorder point:

Reorder Point = Lead Time * Average Demand + Safety Stock Level
= 2 * 110.9 + 17
= 238.8 ≈ 239

Finally, we need to calculate the number of Kanban cards:

Number of Kanban Cards = (Reorder Point / Container Size) + 1
= (239 / 10) + 1
= 24 + 1
= 25 cards

Therefore, the best choice is D) 25 cards. This number of cards should help prevent material shortages while maintaining an efficient Kanban system.

Question 15

Which of the following statements do not correctly describe push manufacturing?
1)The serial operations are independently optimized
2)Compared to pull, push manufacturing is a relatively new concept
3)Forecasts of demands is a significant factor in deciding on material flow
4)It focuses on maximizing inventory investment

Accepted Answer

Push manufacturing is not a new concept compared to pull manufacturing; it has been around for a longer time.

Question 16

Choose the correct statement regarding a Kanban system.

Accepted Answer

The Kanban system operates with the help of Kanban Cards, which place an upper bound on the Work in Process (WIP) inventory. This ensures that there is a limit on the amount of inventory that can be in the production process at one time, thereby reducing waste and improving efficiency. Option A is incorrect because Kanban systems aim to reduce buffer inventory levels to prevent overproduction. Option B is incorrect because maximizing the number of Kanbans would increase inventory levels and contradict the objectives of the system. Option D is incorrect because Kanban systems are widely used in real-life manufacturing environments and have been found to be effective in improving productivity and reducing waste.

Question 17

Which of the following statements regarding the manufacturing systems are correct?
1)For a MRP system, customer demand forecast is essential for material control
2)For a pull system, larger lot sizes and shorter lead times are required
3)For a pull system, a JIT philosophy needs to be solidified within the organization
4)For a Kanban system, each work station need to respond independently from other work stations

Accepted Answer

1) MRP (Material Requirements Planning) systems indeed rely on customer demand forecasts to plan and control materials. 3) A pull system, such as JIT (Just-In-Time), requires a strong commitment to the JIT philosophy throughout the organization to minimize waste and improve efficiency.

Question 18

In general, there are five questions regarding manufacturing and control.Which of the following correctly connects the question with solutions?

Accepted Answer

The answer of In general, there are five questions regarding...

Question 19

For US.Inc., there have been having problems with deciding on the number of Kanban cards in the system.There were several material shortages during the last period.In order to prevent shortages while maintaining an efficient Kanban system, how many Kanban cards should be released in the system?
The lead time is 1 day and the safety stock level is set to 10% of the average demand during the day.The container size is 15 units per container.The following is the demands over the last 10 days:
$$\begin{array} { c | c c c c c c c c c c } 
\text { Days } & 1 & 2 & 3 & 4 & 5 & 6 & 7 & 8 & 9 & 10 \
\hline \begin{array} { c } 
\text { Daily } \
\text { demands }
\end{array} & 100 & 98 & 97 & 120 & 123 & 125 & 121 & 100 & 110 & 105
\end{array}$$

Accepted Answer

To calculate the number of Kanban cards, use the formula: Number of Kanban cards = (Demand during lead time + Safety stock) / Container size. The average daily demand is 109.9 units. Demand during lead time is 109.9 units. Safety stock is 10% of 109.9, which is 10.99 units. Total demand including safety stock is 120.89 units. Dividing by the container size of 15 gives approximately 8 cards.

Question 20

Which of the following statements are the disadvantages of the push system?
1)Increases the work load at the management level
2)Performance is dependent of forecasting ability
3)Increases work-in-process inventory
4)Require less managerial resources at a shop floor level

Accepted Answer

The push system has several disadvantages, including increasing the work load at the management level, dependency on forecasting ability, and increasing work-in-process inventory. However, it does not require less managerial resources at a shop floor level. Therefore, options (1), (2), and (3) are correct, and option (4) is incorrect.

Quiz 8: Push and pull production systems

Which of the following dual-card Kanban rules are not correct? 1) One Kanban per container 2) The more Kanban cards are in the system, the more smoothly manufacturing operates 3) Standardized Containers and loads 4) In some cases, parts can be made without a production Kanban

Depending on who you ask, you will get different answers regarding how to distinguish a pull system from a push system depending.Choose the likely bases for distinguishing a pull system from a push system depending. 1) Information flow 2) Order release 3) Shop floor WIP levels 4) Lot size

Among the following relative disadvantage claims for a pull manufacturing, which one is most likely to be true?

A company implemented a computerized Kanban system that required a considerable amount of asset investment.However, the performance enhancement was not as much as expected.Which of the following correctly explains the reason for this phenomenon?

The dual Kanban system uses more than one type of Kanban cards.Choose the correct type of Kanban cards for a dual Kanban system 1) Withdrawal Kanban 2) Inventory Kanban 3) Supermarket deposit Kanban 4) Transportation Kanban

Among the following relative advantage claims for a pull manufacturing, which ones are likely to be true? 1) The system operates with almost no WIP inventory 2) Less maintenance is required 3) There is not much need to forecast demands 4) Only when it is needed, value is added to incomplete product

Choose the correct statement regarding a Kanban system.

In general, there are five questions regarding manufacturing and control.Which of the following correctly connects the question with solutions?

Which of the following statements are the disadvantages of the push system? 1) Increases the work load at the management level 2) Performance is dependent of forecasting ability 3) Increases work-in-process inventory 4) Require less managerial resources at a shop floor level