Question 1

Lean systems maintain inventory in small lot sizes because small lot sizes:
A) increase pipeline inventory, allowing the organization to buffer against demand uncertainties.
B) increase the quality level of the product.
C) enable schedules to use machine capacities more efficiently.
D) increase manufacturing lead time because of the increase in waiting time.

Accepted Answer

Lean systems rely on just-in-time production and small lot sizes to reduce inventory waste and increase efficiency. By enabling schedules to use machine capacities more efficiently, small lot sizes help to minimize bottlenecks and reduce the risk of overproduction. Option A is incorrect because small lot sizes actually reduce pipeline inventory by minimizing the amount of inventory held in the production process. Option B is incorrect because while small lot sizes can improve quality, this is not the main reason for using them in lean systems. Option D is incorrect because small lot sizes actually decrease manufacturing lead time by allowing for more frequent and efficient production runs.

Question 2

A method in which production of an item begins in advance of customer needs is called:
A) the andon method.
B) the pull method.
C) the jidoka method.
D) the push method.

Accepted Answer

The push method involves manufacturing a product in anticipation of customer demand. This can lead to overproduction and excess inventory if customer demand does not materialize as expected.

Question 3

There are many requirements for the successful implementation of the lean system of production. Which one of the following is not such a requirement?
A) uniform assembly schedule
B) short setup time
C) low machine failure and low defects
D) substantial natural resources

Accepted Answer

The successful implementation of the lean system of production requires resources, but it does not necessarily require substantial natural resources. Other types of resources, such as human resources and equipment, are more important for the implementation of lean production. Therefore, choice D is not a requirement for the successful implementation of the lean system of production.

Question 4

A takt time of 90 seconds generates a process output of:
A) 40 units per hour.
B) 30 units per hour.
C) 4 units per hour.
D) 90 units per hour.

Accepted Answer

Takt time is the available production time divided by the customer demand rate. In this case, the takt time is 90 seconds, which means that the production process has 90 seconds to produce one unit. Therefore, the process output is 1 unit per 90 seconds, or 40 units per hour.

Question 5

The takt time of a process is defined as:
A) the cycle time needed to match the rate of production to the rate of consumption.
B) the total time required to move an item through a process.
C) the time required to change a machine to run a new model.
D) the lead time necessary to notify maintenance that a problem has occurred in an operation.

Accepted Answer

Takt time is a key concept in lean manufacturing and refers to the rate at which a finished product needs to be completed in order to meet customer demand. It is calculated as the available production time divided by the customer demand rate. In other words, it is the cycle time required to match the rate of production to the rate of consumption (customer demand). Therefore, option A is the correct answer. Option B is the definition of total process time, option C is the definition of setup time, and option D is the definition of lead time for maintenance notification.

Question 6

Lean systems try to:
A) produce a product in anticipation of demand.
B) maximize the value added by each of its activities.
C) organize production in large lots to minimize the number of setups.
D) reduce the labor content in all processes.

Accepted Answer

Lean systems aim to maximize value added by each activity and eliminate waste.

Answer: D 
 Lean systems also aim to reduce labor content in processes by eliminating waste and improving efficiency. Choices A and C are not consistent with lean principles.

Question 7

Companies using lean systems generally have:
A) many suppliers to ensure that material shortages never occur.
B) suppliers that are located nearby to decrease delivery lead time.
C) suppliers that are willing to accept short-term contracts.
D) suppliers who are low-cost producers.

Accepted Answer

Lean systems prioritize reducing waste and optimizing efficiency, so having nearby suppliers allows for quicker replenishment of materials and reduces transportation time and costs. Having many suppliers (option A) can actually lead to more inefficiency and complexity in managing relationships and inventory. Suppliers accepting short-term contracts (option C) may not provide consistent and reliable supply, which is crucial in a lean system. Similarly, focusing solely on low-cost producers (option D) may sacrifice quality and reliability.

Question 8

The lean system concept will not work without the proper environment. Which one of the following characteristics is most common to firms that have successfully implemented a lean system?
A) uniform assembly schedules
B) specialized workforce
C) high rates of machine failures
D) longer setup times

Accepted Answer

Uniform assembly schedules are crucial for the success of a lean system because they enable a steady flow of work, minimizing waste and ensuring that resources are used efficiently.

Question 9

The production of 150 units during a 480-minute work shift results in a takt time of:
A) 150 seconds.
B) 192 seconds.
C) 120 seconds.
D) 18.8 seconds.

Accepted Answer

Takt time is calculated by dividing the available production time by the number of units required to be produced. In this case, 480 minutes (or 28,800 seconds) divided by 150 units equals 192 seconds per unit.

Question 10

Using customer demand to activate production of an item or service is called:
A) the andon method.
B) the pull method.
C) the jidoka method.
D) the push method.

Accepted Answer

The pull method is a production method where manufacturers start production only when they receive a customer order or demand. This helps to avoid overproduction and wastage, as production only takes place when there is a customer need.

Question 11

In the Toyota Production System, when a work station needs more material, it is obvious to both the worker and the supplier that material is needed. Further, the amount needed must be understood as well as the delivery time for replenishment.

Accepted Answer

This is a key principle of the Toyota Production System known as "Just-In-Time" or JIT, where materials are delivered to a workstation precisely when they are needed. This helps to reduce waste, improve efficiency, and increase flexibility in manufacturing processes. Clear communication and understanding between workers and suppliers is essential for this system to work effectively.

Question 12

In the Toyota Production System, services and goods are pushed to the next available person or machine to maintain smooth, rapid flow.

Accepted Answer

In the Toyota Production System, the approach is based on a "pull" system, where services and goods are produced based on demand, not pushed to the next stage without regard to demand.

Question 13

Justin Thyme used to run one batch each of 500 As, 300 Bs and 100 Cs every month but now he runs a batch of 5 As, 3 Bs, and 1 C every half day with the use of:
A) single-digit setups.
B) andon lights.
C) mixed-model assembly.
D) push method.

Accepted Answer

The new method of running a batch of 5 As, 3 Bs, and 1 C every half day is an example of mixed-model assembly. This approach allows for greater flexibility and efficiency by producing smaller batches of different products in a single production cycle. It can help reduce wastage, improve quality, and increase productivity. The other options - single-digit setups, andon lights, and push method - do not seem to be directly relevant to the given scenario.

Question 14

The production of 240 units during a 480-minute work shift results in a takt time of:
A) 24 seconds.
B) 30 seconds.
C) 120 seconds.
D) 240 seconds.

Accepted Answer

The answer of The production of 240 units during a...

Question 15

In lean systems, if a defective product is found, which of the following is generally not done?
A) The production line is stopped.
B) The defective unit is passed on to the next workstation.
C) The defective unit is returned to the worker responsible for creating the defect.
D) The production line is made aware of the problem without necessarily stopping the line.

Accepted Answer

In lean systems, if a defective product is found, it is generally not passed on to the next workstation. This would lead to further waste and potential defects downstream. The production line may be stopped temporarily to address the issue and prevent further defects from being produced. The defective unit may be returned to the worker responsible for creating the defect for analysis and improvement. The production line may also be made aware of the issue without necessarily stopping the line, but this should only be done if it does not compromise quality or increase waste.

Question 16

Mistake-proofing is known by the term:
A) andon.
B) muda.
C) jidoka.
D) poka-yoke.

Accepted Answer

Mistake-proofing is also known as poka-yoke in Japanese terminology. Andon is a system for signaling problems in a production line, muda refers to waste reduction, and jidoka is a method for building in quality at each process stage.

Question 17

Lean systems use the standardization of components because standardization:
A) decreases the demand for each component.
B) increases repeatability.
C) increases lot sizes more easily.
D) decreases repeatability.

Accepted Answer

Lean systems aim for process efficiency by eliminating waste and increasing repeatability. Standardization of components allows for consistent processes and easier identification of defects or inefficiencies. Therefore, choice B is the correct answer as it highlights the importance of standardization in achieving greater repeatability.

Question 18

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:
A) andon.
B) muda.
C) jidoka.
D) poka-yoke.

Accepted Answer

Jidoka is the principle of stopping the process when a problem or defect is detected and fixing it before continuing with production. This is a key component of the Toyota Production System and helps to prevent defects from being passed down the line or to the customer. Andon refers to the visual display or alert system used to signal when there is a problem or abnormality in the process, muda refers to waste or non-value-adding activities, and poka-yoke refers to mistake-proofing techniques to prevent errors from occurring.

Question 19

The goal of single-digit setups is to have a setup time:
A) of less than one shift.
B) of less than one hour.
C) of less than 30 minutes.
D) of less than 10 minutes.

Accepted Answer

Single-digit setups aim to reduce setup time to less than 10 minutes.

Question 20

Items to be assembled that fit together only the proper way are an example of:
A) andon.
B) jidoka.
C) poka-yoke.
D) muda.

Accepted Answer

Poka-yoke is a Japanese term that means mistake-proofing or error prevention. The example given in the question, where items only fit together in the proper way, is an example of a poka-yoke. Andon (A) refers to a system of signaling when help is needed in the production process. Jidoka (B) refers to automation that stops the production process when a defect is detected. Muda (D) refers to any activity in the production process that does not add value.

Quiz 6: Lean Systems

Lean systems maintain inventory in small lot sizes because small lot sizes:

A method in which production of an item begins in advance of customer needs is called:

There are many requirements for the successful implementation of the lean system of production. Which one of the following is not such a requirement?

A takt time of 90 seconds generates a process output of:

The takt time of a process is defined as:

Lean systems try to:

Companies using lean systems generally have:

The lean system concept will not work without the proper environment. Which one of the following characteristics is most common to firms that have successfully implemented a lean system?

The production of 150 units during a 480-minute work shift results in a takt time of:

Using customer demand to activate production of an item or service is called:

In the Toyota Production System, when a work station needs more material, it is obvious to both the worker and the supplier that material is needed. Further, the amount needed must be understood as well as the delivery time for replenishment.

In the Toyota Production System, services and goods are pushed to the next available person or machine to maintain smooth, rapid flow.

Justin Thyme used to run one batch each of 500 As, 300 Bs and 100 Cs every month but now he runs a batch of 5 As, 3 Bs, and 1 C every half day with the use of:

The production of 240 units during a 480-minute work shift results in a takt time of:

In lean systems, if a defective product is found, which of the following is generally not done?

Mistake-proofing is known by the term:

Lean systems use the standardization of components because standardization:

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:

The goal of single-digit setups is to have a setup time:

Items to be assembled that fit together only the proper way are an example of: