Question 1

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

Accepted Answer

A)  Design for workflow balance. 
B)  Locate flexible workstations offline. 
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. 
A)  Design for workflow balance. 
B)  Locate flexible workstations offline. 
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 2

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 percent of the demand during lead time, the container size is 5, and the lead time to replenish an order is 5 hours, what the number of kanban card sets is needed?

Accepted Answer

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

Question 3

The key to lean procurement is speed.

Accepted Answer

A) True 
 B)False

Question 4

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?

Accepted Answer

A)  Inventory holding cost will increase nonlinearly 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. 
A)  Inventory holding cost will increase nonlinearly 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 5

The philosophy of making workers personally responsible for the quality of their output and where workers are expected to make the part correctly the first time and to stop the process immediately if there is a problem is called

Accepted Answer

A)  Kaizen 
B)  Personal responsibility 
C)  Lean maintenance 
D)  Worker inspection 
E)  Quality at the source 
A)  Kaizen 
B)  Personal responsibility 
C)  Lean maintenance 
D)  Worker inspection 
E)  Quality at the source

Question 6

The focus of the Toyota Production System is on elimination of waste and reduction in inventory.

Accepted Answer

A) True 
 B)False

Question 7

Uniform plant 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.

Accepted Answer

A) True 
 B)False

Question 8

A philosophy in which similar parts are combined into families, and the processes required to make the parts are arranged in a specialized workcell.

Accepted Answer

A)  Lean manufacturing 
B)  Preventive maintenance 
C)  Lean maintenance 
D)  Group technology 
E)  Quality at the source 
A)  Lean manufacturing 
B)  Preventive maintenance 
C)  Lean maintenance 
D)  Group technology 
E)  Quality at the source

Question 9

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

Accepted Answer

A) True 
 B)False

Question 10

There is less uncertainty in service task times than with manufacturing.

Accepted Answer

A) True 
 B)False

Question 11

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

Accepted Answer

A) True 
 B)False

Question 12

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

Accepted Answer

A)  Improve capacity utilization. 
B)  Build product in anticipation of demand. 
C)  Reduce setup/changeover time. 
D)  Eliminate some fixed costs. 
E)  Implement groupware. 
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 13

An inventory or production control system that uses a signaling device to regulate flows is a

Accepted Answer

A)  Level schedule 
B)  Lean scheduling 
C)  Uniform plant loading 
D)  Kanban 
E)  Kanban pull system 
A)  Level schedule 
B)  Lean scheduling 
C)  Uniform plant loading 
D)  Kanban 
E)  Kanban pull system

Question 14

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

Accepted Answer

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 
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 15

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

Accepted Answer

A) True 
 B)False

Question 16

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

Accepted Answer

A) True 
 B)False

Question 17

Value stream mapping is used to identify all of the value-adding as well as non-value-adding processes that materials are subjected to within a plant.

Accepted Answer

A) True 
 B)False

Question 18

To implement lean production schedules, a firm would do which of the following?

Accepted Answer

A)  Have excess capacity. 
B)  Force demand. 
C)  Hire a consultant. 
D)  Achieve bottom-up management. 
E)  Implement kanban groups. 
A)  Have excess capacity. 
B)  Force demand. 
C)  Hire a consultant. 
D)  Achieve bottom-up management. 
E)  Implement kanban groups.

Question 19

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 percent 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?

Accepted Answer

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

Question 20

Periodic inspection and repair designed to keep equipment reliable is called

Accepted Answer

A)  Kaizen 
B)  Preventive maintenance 
C)  Lean maintenance 
D)  Group technology 
E)  Quality at the source 
A)  Kaizen 
B)  Preventive maintenance 
C)  Lean maintenance 
D)  Group technology 
E)  Quality at the source

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

The key to lean procurement is speed.

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?

The philosophy of making workers personally responsible for the quality of their output and where workers are expected to make the part correctly the first time and to stop the process immediately if there is a problem is called

The focus of the Toyota Production System is on elimination of waste and reduction in inventory.

Uniform plant 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.

A philosophy in which similar parts are combined into families, and the processes required to make the parts are arranged in a specialized workcell.

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

There is less uncertainty in service task times than with manufacturing.

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

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

An inventory or production control system that uses a signaling device to regulate flows is a

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

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

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

Value stream mapping is used to identify all of the value-adding as well as non-value-adding processes that materials are subjected to within a plant.

To implement lean production schedules, a firm would do which of the following?

Periodic inspection and repair designed to keep equipment reliable is called

Introduction

Strategy

Design of Products and Services

Projects

Strategic Capacity Management

Learning Curves

Manufacturing Processes

Facility Layout

Service Processes

Waiting Line Analysis and Simulation

Process Design and Analysis

Six Sigma Quality

Statistical Quality Control

Logistics, Distribution, and Transportation

Global Sourcing and Procurement

The Internet of Things and Erp

Forecasting

Sales and Operations Planning

Inventory Management

Material Requirements Planning

Workcenter Scheduling

Filters

Exam 14: Lean Supply Chains

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

The key to lean procurement is speed.

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?

The philosophy of making workers personally responsible for the quality of their output and where workers are expected to make the part correctly the first time and to stop the process immediately if there is a problem is called

The focus of the Toyota Production System is on elimination of waste and reduction in inventory.

Uniform plant 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.

A philosophy in which similar parts are combined into families, and the processes required to make the parts are arranged in a specialized workcell.

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

There is less uncertainty in service task times than with manufacturing.

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

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

An inventory or production control system that uses a signaling device to regulate flows is a

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

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

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

Value stream mapping is used to identify all of the value-adding as well as non-value-adding processes that materials are subjected to within a plant.

To implement lean production schedules, a firm would do which of the following?

Periodic inspection and repair designed to keep equipment reliable is called

Introduction

Strategy

Design of Products and Services

Projects

Strategic Capacity Management

Learning Curves

Manufacturing Processes

Facility Layout

Service Processes

Waiting Line Analysis and Simulation

Process Design and Analysis

Six Sigma Quality

Statistical Quality Control

Logistics, Distribution, and Transportation

Global Sourcing and Procurement

The Internet of Things and Erp

Forecasting

Sales and Operations Planning

Inventory Management

Material Requirements Planning

Workcenter Scheduling

Filters