Question 1

JIT is typically applied to non-repetitive manufacturing.

Accepted Answer

A) True 
 B)False  False

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 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?

Accepted Answer

27 (26.4)

Question 3

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

Accepted Answer

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 
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 B

Question 4

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

Accepted Answer

A) True 
 B)False

Question 5

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

Accepted Answer

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

Question 6

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

Accepted Answer

A) True 
 B)False

Question 7

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

Accepted Answer

(1)Value must be defined jointly for eac

Question 8

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

Accepted Answer

A) True 
 B)False

Question 9

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

Accepted Answer

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

Question 10

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

Accepted Answer

A) True 
 B)False

Question 11

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

Accepted Answer

A) True 
 B)False

Question 12

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

Accepted Answer

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

Question 13

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?

Accepted Answer

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

Question 14

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

Accepted Answer

A) True 
 B)False

Question 15

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

Accepted Answer

A) True 
 B)False

Question 16

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 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 
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 17

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

Accepted Answer

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

Question 18

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

Accepted Answer

A) True 
 B)False

Question 19

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

Accepted Answer

A) True 
 B)False

Question 20

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

Accepted Answer

A) True 
 B)False

Exam 12: Lean Manufacturing

JIT is typically applied to non-repetitive manufacturing.

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

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

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

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

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

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

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

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

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

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

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

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

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?

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

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

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

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

Introduction to the Field

Operations and Supply Strategy

Project Management

Product and Service Design

Strategic Capacity Management

Process Analysis

Manufacturing Processes

Service Processes

Six Sigma Quality

Supply-Chain Strategy

Logistics and Facility Location

Operations Consulting Reengineering

Enterprise Resource Planning Systems

Demand Management and Forecasting

Aggregate Sales and Operations Planning

Inventory Control

Material Requirements Planning

Scheduling

Constraint Management

Linear Programming Using the Excel Solver

Learning Curves

Job Design Work Measurement

Waiting Line Analysis

Process Capability and Spc

Simulation

Filters