Question 1

If the inventory advantages of a lean system are to be realized,small lot sizes must be used;in order to use small lot sizes,manufacturers must significantly reduce ________ .

Accepted Answer

The answer of If the inventory advantages of a lean...

Question 2

________ are operating systems that maximize the value added of each of their activities by paring unnecessary resources and delays from them.

Accepted Answer

The answer of ________ are operating systems that maximize the...

Question 3

The production of 300 units during a 480-minute work shift results in a takt time of:

Accepted Answer

A) 300 seconds. 
B) 37.5 seconds. 
C) 120 seconds. 
D) 96 seconds. 
A) 300 seconds. 
B) 37.5 seconds. 
C) 120 seconds. 
D) 96 seconds.

Question 4

A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 90 seconds.

Accepted Answer

A) True 
 B)False

Question 5

________ practices include early testing of machine parts that may need to be replaced and making workers responsible for routine minor maintenance of their own equipment.

Accepted Answer

Total Prev

Question 6

The pathway for every service and product in the Toyota Production System must be ________ and ________.

Accepted Answer

The answer of The pathway for every service and product...

Question 7

All improvements to the Toyota Production System must be made using the ________ method.

Accepted Answer

The answer of All improvements to the Toyota Production System...

Question 8

Case 8.3
Mike's Mustard Company uses a Kanban system to manufacture bulk mustard in gallon containers for restaurants.The demand for container lids over an eight-hour production day is 1000 units.The average waiting time for a container of lids is 45 minutes.The processing time for a container of lids is 2 hours,and a container holds 70 lids.
-Use the information in Case 8.3.How many Kanban containers would be required if a 15% policy variable is used?

Accepted Answer

A) 6 or fewer 
B) 7 or 8 
C) 15 to 20 
D) 20 or more 
A) 6 or fewer 
B) 7 or 8 
C) 15 to 20 
D) 20 or more

Question 9

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

Accepted Answer

A) True 
 B)False

Question 10

Implementing a lean system:

Accepted Answer

A) has the advantage that workers have less stress because of the routine,repetitive work they perform. 
B) typically relieves the workers and first-line supervisors from activities such as scheduling,expediting,and productivity improvements. 
C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy. 
D) involves the reorganization of material flows to that of a flexible flow. 
A) has the advantage that workers have less stress because of the routine,repetitive work they perform. 
B) typically relieves the workers and first-line supervisors from activities such as scheduling,expediting,and productivity improvements. 
C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy. 
D) involves the reorganization of material flows to that of a flexible flow.

Question 11

What is the output for a process that has a takt time of 1.25 minutes per unit?

Accepted Answer

60 minutes per hour

Question 12

________ refers to mistake-proofing methods aimed at designing fail-safe systems that minimize human error.

Accepted Answer

The answer of ________ refers to mistake-proofing methods aimed at...

Question 13

The Toyota Production System requires that any process improvements are to be made at the lowest level of the organization.

Accepted Answer

A) True 
 B)False

Question 14

A system that organizes the resources,information flows,and decision rules that enable a firm to realize the benefits of JIT principles is the ________.

Accepted Answer

Just-in-ti

Question 15

In lean systems,work-in-process inventory is a direct result of overproduction and waiting.

Accepted Answer

A) True 
 B)False

Question 16

Which one of the following statements regarding the Toyota production system is best?

Accepted Answer

A) It is particularly well suited for making irregularly used parts and customized "specials." 
B) It is a "push system," with orders pushed out in anticipation of future requirements. 
C) Each container has either a withdrawal or production-ordering Kanban. 
D) It does not use poka yoke or 5S practices. 
A) It is particularly well suited for making irregularly used parts and customized "specials." 
B) It is a "push system," with orders pushed out in anticipation of future requirements. 
C) Each container has either a withdrawal or production-ordering Kanban. 
D) It does not use poka yoke or 5S practices.

Question 17

The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints,while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities.

Accepted Answer

A) True 
 B)False

Question 18

Takt time is the cycle time needed to maximize utilization of an organization's workers and equipment.

Accepted Answer

A) True 
 B)False

Question 19

Case 8.1
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 2000 wheels a day in the production of its products.
-Use the information in Case 8.1.How many Kanban containers would be required if a 10% policy variable is used?

Accepted Answer

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

Question 20

A method in which production of an item begins in advance of customer needs is called:

Accepted Answer

A) the andon method. 
B) the pull method. 
C) the jidoka method. 
D) the push method. 
A) the andon method. 
B) the pull method. 
C) the jidoka method. 
D) the push method.

Exam 8: Lean Systems

If the inventory advantages of a lean system are to be realized,small lot sizes must be used;in order to use small lot sizes,manufacturers must significantly reduce ________ .

________ are operating systems that maximize the value added of each of their activities by paring unnecessary resources and delays from them.

The production of 300 units during a 480-minute work shift results in a takt time of:

A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 90 seconds.

________ practices include early testing of machine parts that may need to be replaced and making workers responsible for routine minor maintenance of their own equipment.

The pathway for every service and product in the Toyota Production System must be ________ and ________.

All improvements to the Toyota Production System must be made using the ________ method.

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

Implementing a lean system:

What is the output for a process that has a takt time of 1.25 minutes per unit?

________ refers to mistake-proofing methods aimed at designing fail-safe systems that minimize human error.

The Toyota Production System requires that any process improvements are to be made at the lowest level of the organization.

A system that organizes the resources,information flows,and decision rules that enable a firm to realize the benefits of JIT principles is the ________.

In lean systems,work-in-process inventory is a direct result of overproduction and waiting.

Which one of the following statements regarding the Toyota production system is best?

The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints,while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities.

Takt time is the cycle time needed to maximize utilization of an organization's workers and equipment.

A method in which production of an item begins in advance of customer needs is called:

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

The pathway for every service and product in the Toyota Production System must be and .