Question 1

In a Kanban system,materials may be withdrawn without a withdrawal card if the operation requiring the material is about to run out of work.

Accepted Answer

A) True 
 B)False

Question 2

The lean system concept will not work without the proper environment.Which one of the following characteristics is most common to firms that have successfully implemented a lean system?

Accepted Answer

A) uniform assembly schedules 
B) specialized workforce 
C) high rates of machine failures 
D) longer setup times 
A) uniform assembly schedules 
B) specialized workforce 
C) high rates of machine failures 
D) longer setup times

Question 3

A Kanban is a card used to control the flow of production in many just-in-time systems.

Accepted Answer

A) True 
 B)False

Question 4

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,manufacturing an item before it is needed is part of which general waste category?

Accepted Answer

A) Inappropriate Processing 
B) Waiting 
C) Inventory 
D) Overproduction 
A) Inappropriate Processing 
B) Waiting 
C) Inventory 
D) Overproduction

Question 5

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 Mike's Mustard require if the containers held only 15 pieces and a 5% policy variable is declared?

Accepted Answer

A) 10 or fewer 
B) 11 to 20 
C) 21 to 30 
D) 31 or more 
A) 10 or fewer 
B) 11 to 20 
C) 21 to 30 
D) 31 or more

Question 6

Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving.

Accepted Answer

A) True 
 B)False

Question 7

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 Mike's Mustard require if a 5% policy variable is used?

Accepted Answer

A) fewer than 2 
B) 5 or 6 
C) 50 to 650 
D) 700 or more 
A) fewer than 2 
B) 5 or 6 
C) 50 to 650 
D) 700 or more

Question 8

An item sells at a rate of 240 units per day.If a plant works one shift per day (480 minutes),what takt time is required for the plant to meet this demand?

Accepted Answer

480 minutes per day

Question 9

The just-in-time (JIT)system is a(n):

Accepted Answer

A) management system of people and procedures to fulfill all delivery deadlines. 
B) production system of small-lot manufacturing to reduce work-in-process inventory. 
C) materials management system for removing all inventories. 
D) integrated system of managing resources,information,and decision processes to eliminate waste. 
A) management system of people and procedures to fulfill all delivery deadlines. 
B) production system of small-lot manufacturing to reduce work-in-process inventory. 
C) materials management system for removing all inventories. 
D) integrated system of managing resources,information,and decision processes to eliminate waste.

Question 10

The just-in-time (JIT)philosophy is the belief that cutting inventory and removing non-value-added activities in operations can eliminate waste.

Accepted Answer

A) True 
 B)False

Question 11

Which of the following is NOT a barrier for an organization when implementing a lean system?

Accepted Answer

A) Workers usually feel as if they have gained autonomy. 
B) Workers can feel increased stress and pressure due to specified cycle times. 
C) Organizational relationships must be reoriented to build close cooperation and trust. 
D) The reward system might require tweaking. 
A) Workers usually feel as if they have gained autonomy. 
B) Workers can feel increased stress and pressure due to specified cycle times. 
C) Organizational relationships must be reoriented to build close cooperation and trust. 
D) The reward system might require tweaking.

Question 12

Five S practices can be applied to both manufacturing and service settings and can include offices,work spaces,tool rooms,and shop floors.

Accepted Answer

A) True 
 B)False

Question 13

Happiness,Inc.uses a Kanban system.The daily demand for the most critical part,the Smylie,is 400 units over an eight-hour production period.The average waiting time for a container of Smylies is 30 minutes.The processing time for a container filled with Smylies is 6 minutes,and a container holds 5 units.If the company wishes to use a 5% policy variable,how many containers are needed?

Accepted Answer

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

Question 14

A Kanban system is an important mechanism for lean system management.Which one of the following statements regarding the operation of a Kanban system is best?

Accepted Answer

A) A typical Kanban used in the JIT system includes information such as item number,unit price,competitor's product name,and its price. 
B) A Kanban can be used to set the order quantity but not the inventory level. 
C) A Kanban and a container move as a pair once production begins at the fabrication process. 
D) An empty container can be exchanged for a full container at the storage location even though no Kanban is on the full container. 
A) A typical Kanban used in the JIT system includes information such as item number,unit price,competitor's product name,and its price. 
B) A Kanban can be used to set the order quantity but not the inventory level. 
C) A Kanban and a container move as a pair once production begins at the fabrication process. 
D) An empty container can be exchanged for a full container at the storage location even though no Kanban is on the full container.

Question 15

Which one of the following is an advantage of lean systems?

Accepted Answer

A) Lean systems reduce equipment needs by using larger lot sizes. 
B) Lean systems can be implemented in any production environment. 
C) Lean systems result in a decrease in safety stock and work-in-process inventory. 
D) Lean systems result in an increase in manufacturing lead times. 
A) Lean systems reduce equipment needs by using larger lot sizes. 
B) Lean systems can be implemented in any production environment. 
C) Lean systems result in a decrease in safety stock and work-in-process inventory. 
D) Lean systems result in an increase in manufacturing lead times.

Question 16

________ is a graphic representation of the Toyota Production System showing all of the essential elements of lean systems that make the TPS work well.

Accepted Answer

The answer of ________ is a graphic representation of the...

Question 17

What are the supply chain implications of the lean system emphasis on small lot sizes?

Accepted Answer

Small lot sizes reduce average inventory

Question 18

Value stream maps consist of a(n)________,a(n)________,and a(n)________.

Accepted Answer

current state drawin

Question 19

Items to be assembled that fit together only the proper way are an example of:

Accepted Answer

A) andon. 
B) jidoka. 
C) poka-yoke. 
D) muda. 
A) andon. 
B) jidoka. 
C) poka-yoke. 
D) muda.

Question 20

Jones Electric Motors uses a Kanban system to make motors for several garage door companies in the southeastern United States.The daily demand for motor housings used in manufacturing is 100 units.The average waiting time for a container of parts is 0.2 day.The processing time for a container of housings is 0.1 day,and a container holds 5 housings.If Jones wishes to use a 10% policy variable,how many containers are needed?

Accepted Answer

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

Exam 8: Lean Systems

In a Kanban system,materials may be withdrawn without a withdrawal card if the operation requiring the material is about to run out of work.

The lean system concept will not work without the proper environment.Which one of the following characteristics is most common to firms that have successfully implemented a lean system?

A Kanban is a card used to control the flow of production in many just-in-time systems.

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,manufacturing an item before it is needed is part of which general waste category?

Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving.

An item sells at a rate of 240 units per day.If a plant works one shift per day (480 minutes),what takt time is required for the plant to meet this demand?

The just-in-time (JIT)system is a(n):

The just-in-time (JIT)philosophy is the belief that cutting inventory and removing non-value-added activities in operations can eliminate waste.

Which of the following is NOT a barrier for an organization when implementing a lean system?

Five S practices can be applied to both manufacturing and service settings and can include offices,work spaces,tool rooms,and shop floors.

A Kanban system is an important mechanism for lean system management.Which one of the following statements regarding the operation of a Kanban system is best?

Which one of the following is an advantage of lean systems?

________ is a graphic representation of the Toyota Production System showing all of the essential elements of lean systems that make the TPS work well.

What are the supply chain implications of the lean system emphasis on small lot sizes?

Value stream maps consist of a(n)________,a(n)________,and a(n)________.

Items to be assembled that fit together only the proper way are an example of:

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

Value stream maps consist of a(n),a(n),and a(n).