Question 1

The goal of single-digit setup is to have a setup completed in fewer than 10 hours.

Accepted Answer

A) True 
 B)False

Question 2

Burdell Salad Dressings uses a Kanban system.The daily demand for corrugated boxes used in packaging its dressings is 300 boxes.The average waiting time for a container of boxes is 0.25 day.The processing time for a container of boxes is 0.1 day,and a container holds 10 boxes.If Burdell wishes to use a 10% policy variable,how many containers are needed?

Accepted Answer

k = @#IMG-DLM& = @#IMG-DLM& =

Question 3

When determining the number of kanban containers,discuss the impact of alpha,the policy variable,on the total amount of inventory in the system.If alpha is set equal to zero,is system inventory zero? What would be required to achieve a system-wide inventory of zero?

Accepted Answer

The policy variable alpha adds safety st

Question 4

Continuous improvement with lean systems:

Accepted Answer

A) involves navigating a ship over treacherous rocks. 
B) requires periodically increasing lot sizes or workforce levels to uncover problems. 
C) entails systematically stressing the system and focusing on problem areas. 
D) focuses exclusively on internal operations without addressing relationships with customers and suppliers. 
A) involves navigating a ship over treacherous rocks. 
B) requires periodically increasing lot sizes or workforce levels to uncover problems. 
C) entails systematically stressing the system and focusing on problem areas. 
D) focuses exclusively on internal operations without addressing relationships with customers and suppliers.

Question 5

Companies using lean systems generally have:

Accepted Answer

A) many suppliers to ensure that material shortages never occur. 
B) suppliers that are located nearby to decrease delivery lead time. 
C) suppliers that are willing to accept short-term contracts. 
D) suppliers who are low-cost producers. 
A) many suppliers to ensure that material shortages never occur. 
B) suppliers that are located nearby to decrease delivery lead time. 
C) suppliers that are willing to accept short-term contracts. 
D) suppliers who are low-cost producers.

Question 6

Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method.

Accepted Answer

A) True 
 B)False

Question 7

After the earthquake and tsunami of 2011,Toyota's suppliers and plants were able to maintain production levels due to their efficiency.

Accepted Answer

A) True 
 B)False

Question 8

Lean systems maintain inventory in small lot sizes because small lot sizes:

Accepted Answer

A) increase pipeline inventory,allowing the organization to buffer against demand uncertainties. 
B) increase the quality level of the product. 
C) enable schedules to use machine capacities more efficiently. 
D) increase manufacturing lead time because of the increase in waiting time. 
A) increase pipeline inventory,allowing the organization to buffer against demand uncertainties. 
B) increase the quality level of the product. 
C) enable schedules to use machine capacities more efficiently. 
D) increase manufacturing lead time because of the increase in waiting time.

Question 9

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

Accepted Answer

A) True 
 B)False

Question 10

The production of 240 units during a 480-minute work shift results in a takt time of:

Accepted Answer

A) 24 seconds. 
B) 30 seconds. 
C) 120 seconds. 
D) 240 seconds. 
A) 24 seconds. 
B) 30 seconds. 
C) 120 seconds. 
D) 240 seconds.

Question 11

________ is a methodology consisting of five workplace practices that are conducive to visual controls and lean production.

Accepted Answer

The answer of ________ is a methodology consisting of five...

Question 12

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

Accepted Answer

A) True 
 B)False

Question 13

Case 8.2
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 3000 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 8.2.How many Kanban containers would Jewel require if a 5% policy variable is used?

Accepted Answer

A) three or fewer 
B) four or five 
C) six or seven 
D) eight or more 
A) three or fewer 
B) four or five 
C) six or seven 
D) eight or more

Question 14

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,using expensive high precision equipment when a simpler machine would suffice is part of which general waste category?

Accepted Answer

A) Motion 
B) Overproduction 
C) Inappropriate Processing 
D) Defects 
A) Motion 
B) Overproduction 
C) Inappropriate Processing 
D) Defects

Question 15

Which of the following statements about the Toyota Production System is best?

Accepted Answer

A) Toyota has built a learning organization over the course of 50 years. 
B) The key to success for Toyota is the set of tools and procedures readily apparent on a plant tour. 
C) The four principles that form the basis to TPS are impossible to replicate. 
D) Toyota has 23 manufacturing plants in North America alone. 
A) Toyota has built a learning organization over the course of 50 years. 
B) The key to success for Toyota is the set of tools and procedures readily apparent on a plant tour. 
C) The four principles that form the basis to TPS are impossible to replicate. 
D) Toyota has 23 manufacturing plants in North America alone.

Question 16

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,which of the following statements is TRUE?

Accepted Answer

A) Jobs with excessive motion should be redesigned. 
B) Work-in-process inventory is the direct result of underutilization of employees. 
C) Manufacturing an item before it is needed helps an organization detect and reduce defects. 
D) Product damage and deterioration result from using expensive high precision equipment. 
A) Jobs with excessive motion should be redesigned. 
B) Work-in-process inventory is the direct result of underutilization of employees. 
C) Manufacturing an item before it is needed helps an organization detect and reduce defects. 
D) Product damage and deterioration result from using expensive high precision equipment.

Question 17

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

Accepted Answer

The organizational issues faced by compa

Question 18

Use of value stream mapping requires construction of a current state drawing,a future state drawing,and an implementation plan.

Accepted Answer

A) True 
 B)False

Question 19

The four bolts that hold the passenger seat in a pickup truck are tightened in a clockwise order beginning with the front right bolt in 24 seconds.This production factoid illustrates which of the following principles of the Toyota Production System?

Accepted Answer

A) All work must be specified as to content. 
B) Every customer-supplier connection must be direct and unambiguous. 
C) The pathway for every service and product must be direct. 
D) Any improvements to the system must be made in accordance with the scientific method. 
A) All work must be specified as to content. 
B) Every customer-supplier connection must be direct and unambiguous. 
C) The pathway for every service and product must be direct. 
D) Any improvements to the system must be made in accordance with the scientific method.

Question 20

In the Toyota Production System,all work must be completely specified as to ________,________,________ and ________.

Accepted Answer

content,se

Exam 8: Lean Systems

The goal of single-digit setup is to have a setup completed in fewer than 10 hours.

When determining the number of kanban containers,discuss the impact of alpha,the policy variable,on the total amount of inventory in the system.If alpha is set equal to zero,is system inventory zero? What would be required to achieve a system-wide inventory of zero?

Continuous improvement with lean systems:

Companies using lean systems generally have:

Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method.

After the earthquake and tsunami of 2011,Toyota's suppliers and plants were able to maintain production levels due to their efficiency.

Lean systems maintain inventory in small lot sizes because small lot sizes:

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

The production of 240 units during a 480-minute work shift results in a takt time of:

________ is a methodology consisting of five workplace practices that are conducive to visual controls and lean production.

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

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,using expensive high precision equipment when a simpler machine would suffice is part of which general waste category?

Which of the following statements about the Toyota Production System is best?

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,which of the following statements is TRUE?

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

Use of value stream mapping requires construction of a current state drawing,a future state drawing,and an implementation plan.

The four bolts that hold the passenger seat in a pickup truck are tightened in a clockwise order beginning with the front right bolt in 24 seconds.This production factoid illustrates which of the following principles of the Toyota Production System?

In the Toyota Production System,all work must be completely specified as to ________,________,________ and ________.

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

Filters

In the Toyota Production System,all work must be completely specified as to ,, and .