Exam 6: Lean Systems

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?

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

With respect to lean systems,what is the advantage of standardized components?

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?

What are the four underlying principles of the Toyota Production System?

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?

________ 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.

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.

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

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

In the Toyota Production System,services and goods flow to the next available person or machine to maintain smooth,rapid flow.

In manufacturing systems,one way to achieve continuous improvement can be to maintain low inventories,and periodically cut safety stocks almost to zero.

The takt time of a process is defined as:

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?

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

An OWMM arrangement reduces labor requirements but increases inventory.

Group technology collects similar parts into families and organizes machine tools into separate cells.

A ________ is based on both a withdrawal card and a production-order card,to control inventory quantities more closely.

In lean systems,the need for single-digit setups is driven by the desire for small lot sizes.

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?