Question 1

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

Accepted Answer

Small lot sizes reduce average inventory

Question 2

List and briefly define the 5S Practices that serve as an enabler and essential foundation of lean systems.

Accepted Answer

Refer to T

Question 3

"When in doubt,weed it out" describes which 5S element?

Accepted Answer

A) Sort 
B) Straighten 
C) Shine 
D) Standardize 
A) Sort 
B) Straighten 
C) Shine 
D) Standardize

Question 4

An important mechanism for lean systems is a Kanban system.Which one of the following statements correctly describes the behavior of a two-card Kanban system?

Accepted Answer

A) A withdrawal Kanban is issued to authorize production in the fabrication process. 
B) A production-ordering Kanban authorizes the assembly process to remove the materials from the storage location. 
C) The fabrication process produces certain units defined by the lot size and pushes them down to the assembly process. 
D) Containers must never be removed from the storage location without an authorizing withdrawal Kanban. 
A) A withdrawal Kanban is issued to authorize production in the fabrication process. 
B) A production-ordering Kanban authorizes the assembly process to remove the materials from the storage location. 
C) The fabrication process produces certain units defined by the lot size and pushes them down to the assembly process. 
D) Containers must never be removed from the storage location without an authorizing withdrawal Kanban.

Question 5

Kaizen is the Japanese term for continuous improvement.

Accepted Answer

A) True 
 B)False

Question 6

A value stream map shows the flows of materials and information and the lines of responsibility and authority.

Accepted Answer

A) True 
 B)False

Question 7

A ________ assembly line produces a mix of models in smaller lots.

Accepted Answer

The answer of A ________ assembly line produces a mix...

Question 8

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

Accepted Answer

A) True 
 B)False

Question 9

In the Toyota Production System,when a work station needs more material,it is obvious to both the worker and the supplier that material is needed.Further,the amount needed must be understood as well as the delivery time for replenishment.

Accepted Answer

A) True 
 B)False

Question 10

________ refers to a form of supplier partnership that places a supplier representative,who is empowered to plan and schedule the replenishment of materials from the supplier,in the customer's plant on a full-time basis.

Accepted Answer

The answer of ________ refers to a form of supplier...

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

Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method.

Accepted Answer

A) True 
 B)False

Question 13

All improvements to the Toyota Production System must be made at the ________ level.

Accepted Answer

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

Question 14

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 15

Scenario 6.1
El Gran Raton,the producers of the finest carpincho wallets in all of Argentina,examined their production process in the form of a value stream map,displayed below.   Daniel Penfield artist
-Use the value stream map to conduct a complete analysis of the carpincho wallet production process.Calculate all raw material and WIP lead times and determine overall process capacity assuming El Gran Raton uses a batch size of 300 units.If a single carpincho wallet were ordered today,how long before it would reach the back pocket of the delighted customer if his order is but one of an average of 2230 orders (all for a single wallet)during an average 5 day work week.*Assume that the days indicated on the lead time ladder are based on a different batch size and not applicable to the 300 unit batch currently in use.*

Accepted Answer

Using a batch size of 300 units,the capa

Question 16

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

Accepted Answer

A) True 
 B)False

Question 17

________ is the philosophy that waste can be eliminated by cutting unnecessary inventory and removing non-value-adding activities in operations.

Accepted Answer

The answer of ________ is the philosophy that waste can...

Question 18

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 19

Which of the following statements about the Toyota Production System is BEST?

Accepted Answer

A) Toyota has built a learning organization over the course of 50 years. 
B) The key to success for Toyota is the set of tools and procedures readily apparent on a plant tour. 
C) The four principles that form the basis to TPS are impossible to replicate. 
D) Toyota has 23 manufacturing plants in North America alone. 
A) Toyota has built a learning organization over the course of 50 years. 
B) The key to success for Toyota is the set of tools and procedures readily apparent on a plant tour. 
C) The four principles that form the basis to TPS are impossible to replicate. 
D) Toyota has 23 manufacturing plants in North America alone.

Question 20

What did the production manager say to the pile of scrapped material?

Accepted Answer

A) "Hello muda." 
B) "Hello fadduh." 
C) "We need more kanbans." 
D) "JIT II Brute?" 
A) "Hello muda." 
B) "Hello fadduh." 
C) "We need more kanbans." 
D) "JIT II Brute?"

Exam 6: Lean Systems

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

List and briefly define the 5S Practices that serve as an enabler and essential foundation of lean systems.

"When in doubt,weed it out" describes which 5S element?

An important mechanism for lean systems is a Kanban system.Which one of the following statements correctly describes the behavior of a two-card Kanban system?

Kaizen is the Japanese term for continuous improvement.

A value stream map shows the flows of materials and information and the lines of responsibility and authority.

A ________ assembly line produces a mix of models in smaller lots.

Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots.

In the Toyota Production System,when a work station needs more material,it is obvious to both the worker and the supplier that material is needed.Further,the amount needed must be understood as well as the delivery time for replenishment.

________ refers to a form of supplier partnership that places a supplier representative,who is empowered to plan and schedule the replenishment of materials from the supplier,in the customer's plant on a full-time basis.

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

Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method.

All improvements to the Toyota Production System must be made at the ________ level.

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

________ is the philosophy that waste can be eliminated by cutting unnecessary inventory and removing non-value-adding activities in operations.

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

Which of the following statements about the Toyota Production System is BEST?

What did the production manager say to the pile of scrapped material?

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