Question 1

Lean systems do not need stable master production schedules.

Accepted Answer

A) True 
 B)False

Question 2

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 3

Case 6.2
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 6.2.How many Kanban containers would Jewel require if a 10% policy variable is used?

Accepted Answer

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

Question 4

Push systems are often used in firms with highly repetitive processes and well defined work flows of standardized items.

Accepted Answer

A) True 
 B)False

Question 5

A ________ is a workstation in which a worker operates several different machines simultaneously to achieve a line flow.

Accepted Answer

one-worker

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

Champion Cooling Company uses a kanban system at their two locations in the Oklahoma City Metroplex.The daily demand for fans is 2000 at each location and management insists on using the same alpha level (0.1)at both locations.Location Reno uses containers that hold 20 items and takes 0.04 of a day to process a container.It takes 0.07 of a day to get a container filled and for it to wait during its cycle.Location Western uses containers that hold 24 items and takes 0.02 of a day to process a container.It takes 0.08 of a day to get a container filled and for it to wait during its cycle.Which location has the higher level of inventory? Assume that both locations round up to the next highest integer number of containers.

Accepted Answer

kReno = @#IMG-DLM& = @#IMG-DLM& = 12.1 →

Question 8

________ is the leveling of production load by both volume and product mix.

Accepted Answer

The answer of ________ is the leveling of production load...

Question 9

The rack at my assembly station that holds rear view mirrors is empty,so a runner wheels it away and replaces it with a new rack,fully populated with rear view mirrors.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 10

________ 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 11

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 12

Scenario 6.1 shows a value stream map with the picture separated into a top and bottom halves,each encircled by a dashed line.The bottom half of the picture could best be described as representing the:

Accepted Answer

A) flow of information. 
B) flow of money. 
C) flow of material. 
D) flow of power. 
A) flow of information. 
B) flow of money. 
C) flow of material. 
D) flow of power.

Question 13

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 14

The goal of single-digit setups is to have a setup time:

Accepted Answer

A) of less than one shift. 
B) of less than one hour. 
C) of less than 30 minutes. 
D) of less than 10 minutes. 
A) of less than one shift. 
B) of less than one hour. 
C) of less than 30 minutes. 
D) of less than 10 minutes.

Question 15

While lean systems work very well for manufacturing systems,they cannot be applied to service systems.

Accepted Answer

A) True 
 B)False

Question 16

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

Accepted Answer

A) using larger containers that can hold more parts than before 
B) less demand for the part held by the container 
C) faster processing time for the part held by the container 
D) increased waiting time for the container 
A) using larger containers that can hold more parts than before 
B) less demand for the part held by the container 
C) faster processing time for the part held by the container 
D) increased waiting time for the container

Question 17

Using customer demand to activate production of an item or service 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.

Question 18

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

Accepted Answer

The answer of Automatically stopping the process when something is...

Question 19

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 20

Productivity tends to increase when components are standardized because each worker performs a standardized task or work method more often each day.

Accepted Answer

A) True 
 B)False

Exam 6: Lean Systems

Lean systems do not need stable master production schedules.

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

Push systems are often used in firms with highly repetitive processes and well defined work flows of standardized items.

A ________ is a workstation in which a worker operates several different machines simultaneously to achieve a line flow.

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

________ is the leveling of production load by both volume and product mix.

The rack at my assembly station that holds rear view mirrors is empty,so a runner wheels it away and replaces it with a new rack,fully populated with rear view mirrors.This production factoid illustrates which of the following principles of the Toyota Production System?

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

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.

Scenario 6.1 shows a value stream map with the picture separated into a top and bottom halves,each encircled by a dashed line.The bottom half of the picture could best be described as representing the:

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?

The goal of single-digit setups is to have a setup time:

While lean systems work very well for manufacturing systems,they cannot be applied to service systems.

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

Using customer demand to activate production of an item or service is called:

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

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

Productivity tends to increase when components are standardized because each worker performs a standardized task or work method more often each day.

Using Operations to Create Value

Process Strategy and Analysis

Quality and Performance

Capacity Planning

Constraint Management

Project Management

Forecasting

Inventory Management

Operations Planning and Scheduling

Resource Planning

Supply Chain Design

Supply Chain Logistic Networks

Supply Chain Integration

Supply Chain Sustainability

Decision Making

Waiting Lines

Special Inventory Models

Linear Programming

Simulation

Financial Analysis

Acceptance Sampling Plans

Measuring Output Rates

Learning Curve Analysis

Operations Scheduling

Layout

Filters

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