Question 1

Group technology is a philosophy wherein similar parts are grouped together and the processes required to make the parts are arranged as a work cell.

Accepted Answer

A) True 
 B)False

Question 2

Uniform plant loading means smoothing the production flow to dampen schedule variation.This practice is also known by which Japanese name?

Accepted Answer

The answer of Uniform plant loading means smoothing the production...

Question 3

In a lean production system we expect to see which of the following?

Accepted Answer

A) No "just-in-case" extra inventory 
B) More "just-in-case" extra inventory 
C) More parts and fewer standardized product configurations 
D) Managers being held responsible for quality of the work turned out 
E) Closer management/labor relationships 
A) No "just-in-case" extra inventory 
B) More "just-in-case" extra inventory 
C) More parts and fewer standardized product configurations 
D) Managers being held responsible for quality of the work turned out 
E) Closer management/labor relationships

Question 4

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

Accepted Answer

A) Design for work flow balance 
B) Locate flexible workstations off line 
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 work flow balance 
B) Locate flexible workstations off line 
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 5

Which of the following are key inventory reduction targets under lean production?

Accepted Answer

A) FIFO inventory 
B) Hidden inventory 
C) Safety stock 
D) Lost inventory 
E) Ladder inventory 
A) FIFO inventory 
B) Hidden inventory 
C) Safety stock 
D) Lost inventory 
E) Ladder inventory

Question 6

Lean production replaced JIT in the 1990s because JIT did not address the problem of reducing waste.

Accepted Answer

A) True 
 B)False

Question 7

In Japanese manufacturing automation and robotics are used extensively to perform dull or routine jobs so employees are free to focus on important improvement tasks.

Accepted Answer

A) True 
 B)False

Question 8

Subcontractor networks are not very important in Japanese manufacturing.

Accepted Answer

A) True 
 B)False

Question 9

Explain why lean manufacturing requires a stable demand environment.

Accepted Answer

The text refers to "uniform plant loadin

Question 10

In setting up a kanban control system and you need to determine the number of kanban card sets needed.If the expected demand during lead time is 50 per hour,the safety stock is 20% of the demand during lead time,the container size is 4.If the lead time to replenish an order is 2 hours,what number of kanban card sets is needed?

Accepted Answer

The answer of In setting up a kanban control system...

Question 11

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 50 per hour,the safety stock is 20% of the demand during lead time,the container size is 4.If the lead time to replenish an order is 8 hours,what number of Kanban card sets is needed?

Accepted Answer

A) 60 
B) 80 
C) 90 
D) 120 
E) 150 
A) 60 
B) 80 
C) 90 
D) 120 
E) 150

Question 12

In implementing a lean production system you should work with suppliers to do which of the following?

Accepted Answer

A) Calculate lead times 
B) Quality circles 
C) Freeze windows 
D) Make frequent deliveries 
E) Achieve bottom-round management 
A) Calculate lead times 
B) Quality circles 
C) Freeze windows 
D) Make frequent deliveries 
E) Achieve bottom-round management

Question 13

Company unions in Japan exist to foster a cooperative relationship with management.

Accepted Answer

A) True 
 B)False

Question 14

Uniform 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 15

Which of the following is a lean production technique that has been successfully applied in service firms?

Accepted Answer

A) Decision trees 
B) Leveling the facility load 
C) Linear programming 
D) Fully utilizing capacity 
E) Backflushing 
A) Decision trees 
B) Leveling the facility load 
C) Linear programming 
D) Fully utilizing capacity 
E) Backflushing

Question 16

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

Accepted Answer

A) Heijunka 
B) Motion 
C) Excess capacity 
D) Underproduction 
E) Excess demand 
A) Heijunka 
B) Motion 
C) Excess capacity 
D) Underproduction 
E) Excess demand

Question 17

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 1,200 per hour.You estimate the safety stock should be set at 5% of the demand during lead time.The tote trays used as containers can hold 2 units of stock and the lead time to replenish an order is 10 hours.Which of the following is the number of Kanban card sets necessary to support this situation?

Accepted Answer

A) 5,000 
B) 5,500 
C) 6,300 
D) 6,500 
E) 7,000 
A) 5,000 
B) 5,500 
C) 6,300 
D) 6,500 
E) 7,000

Question 18

One of the few JIT techniques that do not work well in service firms is demand-pull scheduling.

Accepted Answer

A) True 
 B)False

Question 19

In the textbook the expression "quality at the source" means that we need to purchase the best quality a supplier or vendor can provide.

Accepted Answer

A) True 
 B)False

Question 20

Respect for people is a key to the Japanese improvement ideas in manufacturing.

Accepted Answer

A) True 
 B)False

Exam 12: Lean Manufacturing

Group technology is a philosophy wherein similar parts are grouped together and the processes required to make the parts are arranged as a work cell.

Uniform plant loading means smoothing the production flow to dampen schedule variation.This practice is also known by which Japanese name?

In a lean production system we expect to see which of the following?

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

Which of the following are key inventory reduction targets under lean production?

Lean production replaced JIT in the 1990s because JIT did not address the problem of reducing waste.

In Japanese manufacturing automation and robotics are used extensively to perform dull or routine jobs so employees are free to focus on important improvement tasks.

Subcontractor networks are not very important in Japanese manufacturing.

Explain why lean manufacturing requires a stable demand environment.

In implementing a lean production system you should work with suppliers to do which of the following?

Company unions in Japan exist to foster a cooperative relationship with management.

Uniform 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.

Which of the following is a lean production technique that has been successfully applied in service firms?

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

One of the few JIT techniques that do not work well in service firms is demand-pull scheduling.

In the textbook the expression "quality at the source" means that we need to purchase the best quality a supplier or vendor can provide.

Respect for people is a key to the Japanese improvement ideas in manufacturing.

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