Exam 6: Lean Systems

Case 6.2 The Jewel Golf Club Company, which recently began using a Kanban system, has had problems with high inventory levels of one of the handle grips used to make several versions of its clubs. Daily demand for the grip is 3,000 units, average waiting time during production is 0.20 day, processing time is 0.10 day per container, and a container holds 150 grips. -Use the information in Case 6.2. How many Kanban containers would Jewel require if a 5% policy variable is used?

How does Toyota's two-card kanban system work?

One tactic of Total Preventive Maintenance (TPM) is to make workers responsible for routine minor maintenance of their own equipment.

In a lean system, an item that is manufactured before it is needed is not considered waste, because it helps keep material flowing through the system.

Scenario 6.1 El Gran Raton, the producers of the finest carpincho wallets in all of Argentina, examined their production process in the form of a value stream map, displayed below. Daniel Penfield artist -Use Scenario 6.1 to determine the total production lead time for carpincho wallets.

Five S practices can be applied to both manufacturing and service settings and can include offices, work spaces, tool rooms, and shop floors.

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called jidoka.

Companies using lean systems generally have:

What are the organizational issues companies must address before implementing a lean system?

Which of the following statements is True with regard to the eight types of waste that must be eliminated to implement lean systems?

________ is the leveling of production load by both volume and product mix.

With a batch size of 300 units, what is the capacity of process A as shown in Scenario 6.1?

Often in value stream mapping, analysts must rely on process information from shop floor workers rather than direct observation in an effort to quickly develop a work plan and accelerate implementing the improved process.

Productivity tends to increase when components are standardized because each worker performs a standardized task or work method more often each day.

Preventive maintenance is typically given very low priority in just-in-time systems.

Takt time is the cycle time needed to match the rate of production to the rate of sales.

In manufacturing systems, one way to achieve continuous improvement can be to maintain low inventories, and periodically cut safety stocks almost to zero.

To complete the current state drawing of a process, a map of the current situation is developed, including such items as material and information flows, process times, setup times, batch sizes, scrap rates, and number of people required.

Long production runs, poor material flows, and processes that are not tightly linked to one another can cause over 90% of a product's lead time to be spent waiting.

Case 6.1 The Edward James Toy Company uses a Kanban system to make plastic wheels that are a component of several toys. The waiting time for a container of the wheels during production is 0.25 day; average processing time is 0.15 day per container. Each container holds 200 wheels. The company uses 2,000 wheels a day in the production of its products. -Use the information in Case 6.1. How many Kanban containers would be required if a 10% policy variable is used?