Question 1

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

Accepted Answer

A) True 
 B)False

Question 2

Weeding out unnecessary items,neatly arranging what's left,and cleaning the work area are components of:

Accepted Answer

A) a Kanban system. 
B) a constraint management system. 
C) mixed-model assembly. 
D) a 5S program. 
A) a Kanban system. 
B) a constraint management system. 
C) mixed-model assembly. 
D) a 5S program.

Question 3

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

Accepted Answer

A) 150 seconds. 
B) 192 seconds. 
C) 120 seconds. 
D) 18.8 seconds. 
A) 150 seconds. 
B) 192 seconds. 
C) 120 seconds. 
D) 18.8 seconds.

Question 4

A plant's manufacturing process has a takt time of 90 seconds per unit.This results in a process output of how many units per hour?

Accepted Answer

60 minutes per hour x 60 secon

Question 5

Which of the following actions would decrease the number of containers in use in a Kanban system?

Accepted Answer

A) smaller containers that can hold fewer parts than before 
B) higher demand for the part held by the container 
C) increased waiting time for the container 
D) faster processing times for the part held by the container 
A) smaller containers that can hold fewer parts than before 
B) higher demand for the part held by the container 
C) increased waiting time for the container 
D) faster processing times for the part held by the container

Question 6

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

Accepted Answer

A) True 
 B)False

Question 7

The ________ method activates production of a service or item based on customer demand.

Accepted Answer

The answer of The ________ method activates production of a...

Question 8

Using expensive,high precision equipment,even when simpler machines would suffice,is encouraged when lean systems are implemented,because this is the only way high quality manufacturing can be achieved.

Accepted Answer

A) True 
 B)False

Question 9

Lean systems do not need stable master production schedules.

Accepted Answer

A) True 
 B)False

Question 10

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

Accepted Answer

A) True 
 B)False

Question 11

Briefly outline the steps to be followed in evaluating and improving a process using value stream mapping.

Accepted Answer

VSM analysts begin by selecting a produc

Question 12

What are some of the approaches used to achieve the high quality levels associated with lean systems?

Accepted Answer

Quality at the source is one principle a

Question 13

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

Accepted Answer

A) True 
 B)False

Question 14

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

Accepted Answer

A) True 
 B)False

Question 15

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.

Accepted Answer

A) True 
 B)False

Question 16

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.

Accepted Answer

A) True 
 B)False

Question 17

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.

Accepted Answer

A) True 
 B)False

Question 18

The final assembly schedule in a lean system:

Accepted Answer

A) should be developed for each product independent of the process requirements for the other products. 
B) strives to create a uniform flow at the work centers in the plant. 
C) avoids the use of small lot sizes because they create many production orders and cause confusion. 
D) allows daily changes in demand levels,regardless of size,to be incorporated immediately into the work center schedules. 
A) should be developed for each product independent of the process requirements for the other products. 
B) strives to create a uniform flow at the work centers in the plant. 
C) avoids the use of small lot sizes because they create many production orders and cause confusion. 
D) allows daily changes in demand levels,regardless of size,to be incorporated immediately into the work center schedules.

Question 19

Just-in-time (JIT)systems rely on inspectors to inspect quality into the product.

Accepted Answer

A) True 
 B)False

Question 20

When implementing a lean system:

Accepted Answer

A) managers can mitigate some of the effects of worker stress by judiciously using safety stocks and emphasizing material flows rather than worker pace. 
B) management should base the reward system on production volume. 
C) the plant layout is the only environmental characteristic that need not be analyzed. 
D) it is critical to develop a master production schedule that changes frequently as forecasts change. 
A) managers can mitigate some of the effects of worker stress by judiciously using safety stocks and emphasizing material flows rather than worker pace. 
B) management should base the reward system on production volume. 
C) the plant layout is the only environmental characteristic that need not be analyzed. 
D) it is critical to develop a master production schedule that changes frequently as forecasts change.

Exam 8: Lean Systems

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

Weeding out unnecessary items,neatly arranging what's left,and cleaning the work area are components of:

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

A plant's manufacturing process has a takt time of 90 seconds per unit.This results in a process output of how many units per hour?

Which of the following actions would decrease the number of containers in use in a Kanban system?

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

The ________ method activates production of a service or item based on customer demand.

Using expensive,high precision equipment,even when simpler machines would suffice,is encouraged when lean systems are implemented,because this is the only way high quality manufacturing can be achieved.

Lean systems do not need stable master production schedules.

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

Briefly outline the steps to be followed in evaluating and improving a process using value stream mapping.

What are some of the approaches used to achieve the high quality levels associated with lean systems?

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

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

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.

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.

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.

The final assembly schedule in a lean system:

Just-in-time (JIT)systems rely on inspectors to inspect quality into the product.

When implementing a lean system:

Using Operations to Compete

Project Management

Process Strategy

Process Analysis

Quality and Performance

Capacity Planning

Constraint Management

Supply Chain Inventory Management

Supply Chain Design

Supply Chain Location Decisions

Supply Chain Integration

Supply Chain Sustainability and Humanitarian Logistics

Forecasting

Operations Planning and Scheduling

Resource Planning

Decision Making

Waiting Line

Special Inventory Models

Linear Programming

Simulation

Financial Analysis

Acceptance Sampling Plans

Measuring Output Rates

Learning Curve Analysis

Operations Scheduling

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