Question 1

Choose a simple,common process and create a value stream map containing the current state,plus a realistic future state,and implementation plan.

Accepted Answer

Answers will vary.See the outline below

Question 2

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 3

A power cord that can be plugged in only one way is an example of a poka-yoke.

Accepted Answer

A) True 
 B)False

Question 4

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

Accepted Answer

A) True 
 B)False

Question 5

Use the data in Scenario 6.1 to calculate the per unit processing time for Process A if El Gran Raton decides to run a batch size of 360 units.The per unit time is:

Accepted Answer

A) 310 seconds. 
B) 46.67 seconds. 
C) 340 seconds. 
D) 696.67 seconds. 
A) 310 seconds. 
B) 46.67 seconds. 
C) 340 seconds. 
D) 696.67 seconds.

Question 6

What is the difference between the "push" and "pull" methods of material flow? Which method does lean systems use?

Accepted Answer

With the pull method,customer demand (an

Question 7

In a lean system,the key to continuous improvement is the understanding that excess capacity or inventory hides problems on the shop floor and thus prevents waste sources from being identified and eliminated.

Accepted Answer

A) True 
 B)False

Question 8

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

Accepted Answer

A) True 
 B)False

Question 9

If frequent,small shipments of purchased items cannot be arranged with suppliers,large inventory savings for these items cannot be realized.

Accepted Answer

A) True 
 B)False

Question 10

Champion Cooling Company uses a kanban system at their location in the Oklahoma City Metroplex.The daily demand for fans is 2000 and management insists on using an alpha level of 0.1.They use containers that hold 24 items and takes 0.02 of a day to process.It takes 0.08 of a day to get a container filled and for it to wait during its cycle.How many containers should they use? If they use the nearest integer value number of containers,what is the actual system alpha?

Accepted Answer

k = @#IMG-DLM& = @#IMG-DLM& = 9.16 → 9 containers

Question 11

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 12

As the average processing time per container of parts increases,fewer containers are needed in a Kanban system.

Accepted Answer

A) True 
 B)False

Question 13

Case 6.1
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 6.1.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 14

Case 6.1
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 6.1.Using a policy variable of 5%,calculate the number of Kanban containers needed for the wheels.

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 15

Lean systems use the standardization of components because standardization:

Accepted Answer

A) decreases the demand for each component. 
B) increases repeatability. 
C) allows for small lot sizes more easily. 
D) decreases repeatability. 
A) decreases the demand for each component. 
B) increases repeatability. 
C) allows for small lot sizes more easily. 
D) decreases repeatability.

Question 16

What is group technology and what advantages are accrued from its use?

Accepted Answer

The theory is to group parts or products

Question 17

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:

Accepted Answer

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

Question 18

Which of the following statements is TRUE with regard to the eight types of waste that must be eliminated to implement lean systems?

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 19

The final assembly schedule in a lean system:

Accepted Answer

A) should be developed for each product independent of the process requirements for the other products. 
B) strives to create a uniform flow at the work centers in the plant. 
C) avoids the use of small lot sizes because they create many production orders and cause confusion. 
D) allows daily changes in demand levels,regardless of size,to be incorporated immediately into the work center schedules. 
A) should be developed for each product independent of the process requirements for the other products. 
B) strives to create a uniform flow at the work centers in the plant. 
C) avoids the use of small lot sizes because they create many production orders and cause confusion. 
D) allows daily changes in demand levels,regardless of size,to be incorporated immediately into the work center schedules.

Question 20

A lean system's ________ refers to the cycle time needed to match the rate of production to the rate of sales or consumption.

Accepted Answer

The answer of A lean system's ________ refers to the...

Exam 6: Lean Systems

Choose a simple,common process and create a value stream map containing the current state,plus a realistic future state,and implementation plan.

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

A power cord that can be plugged in only one way is an example of a poka-yoke.

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

Use the data in Scenario 6.1 to calculate the per unit processing time for Process A if El Gran Raton decides to run a batch size of 360 units.The per unit time is:

What is the difference between the "push" and "pull" methods of material flow? Which method does lean systems use?

In a lean system,the key to continuous improvement is the understanding that excess capacity or inventory hides problems on the shop floor and thus prevents waste sources from being identified and eliminated.

Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families.

If frequent,small shipments of purchased items cannot be arranged with suppliers,large inventory savings for these items cannot be realized.

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

As the average processing time per container of parts increases,fewer containers are needed in a Kanban system.

Lean systems use the standardization of components because standardization:

What is group technology and what advantages are accrued from its use?

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as:

Which of the following statements is TRUE with regard to the eight types of waste that must be eliminated to implement lean systems?

The final assembly schedule in a lean system:

A lean system's ________ refers to the cycle time needed to match the rate of production to the rate of sales or consumption.

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