Question 1

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 2

Five S practices can enable workers to visually see everything differently,prioritize tasks,and achieve a greater degree of focus.

Accepted Answer

A) True 
 B)False

Question 3

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 4

The list of five S practices includes ________,________,________,________ and ________.

Accepted Answer

sort,strai

Question 5

The ________ method activates production of a service or item based on customer demand.

Accepted Answer

The answer of The ________ method activates production of a...

Question 6

Companies using lean systems generally have:

Accepted Answer

A) many suppliers to ensure that material shortages never occur. 
B) suppliers that are located nearby to decrease delivery lead time. 
C) suppliers that are willing to accept short-term contracts. 
D) suppliers who are low-cost producers. 
A) many suppliers to ensure that material shortages never occur. 
B) suppliers that are located nearby to decrease delivery lead time. 
C) suppliers that are willing to accept short-term contracts. 
D) suppliers who are low-cost producers.

Question 7

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 8

Explain the meaning of the term takt time,and use a numerical example to illustrate.

Accepted Answer

Takt time is the cycle time needed to ma

Question 9

There are many requirements for the successful implementation of the lean system of production.Which one of the following is not such a requirement?

Accepted Answer

A) uniform assembly schedule 
B) short setup time 
C) low machine failure and low defects 
D) substantial natural resources 
A) uniform assembly schedule 
B) short setup time 
C) low machine failure and low defects 
D) substantial natural resources

Question 10

A plant's manufacturing process has a takt time of 72 seconds per unit.This results in a process output of how many units per hour?

Accepted Answer

60 minutes per hour × 60 secon

Question 11

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 12

Some Kanban systems are set up without Kanban cards,and use the material containers or open spaces in a work area to withdraw materials.

Accepted Answer

A) True 
 B)False

Question 13

Implementing a lean system:

Accepted Answer

A) has the advantage that workers have less stress because of the routine,repetitive work they perform. 
B) typically relieves the workers and first-line supervisors from activities such as scheduling,expediting,and productivity improvements. 
C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy. 
D) involves the reorganization of material flows to that of a flexible flow. 
A) has the advantage that workers have less stress because of the routine,repetitive work they perform. 
B) typically relieves the workers and first-line supervisors from activities such as scheduling,expediting,and productivity improvements. 
C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy. 
D) involves the reorganization of material flows to that of a flexible flow.

Question 14

In a ________ system based on other Kanban signals,an empty space signals a need to fill it.

Accepted Answer

The answer of In a ________ system based on other...

Question 15

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 20 items and takes 0.04 of a day to process.It takes 0.07 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& = 12.1 → 12 containers

Question 16

Lean systems maintain inventory in small lot sizes because small lot sizes:

Accepted Answer

A) increase pipeline inventory,allowing the organization to buffer against demand uncertainties. 
B) increase the quality level of the product. 
C) enable schedules to use machine capacities more efficiently. 
D) increase manufacturing lead time because of the increase in waiting time. 
A) increase pipeline inventory,allowing the organization to buffer against demand uncertainties. 
B) increase the quality level of the product. 
C) enable schedules to use machine capacities more efficiently. 
D) increase manufacturing lead time because of the increase in waiting time.

Question 17

Which one of the following statements regarding the Toyota production system is BEST?

Accepted Answer

A) It is particularly well suited for making irregularly used parts and customized "specials." 
B) It is a "push system," with orders pushed out in anticipation of future requirements. 
C) Each container has either a withdrawal or production-ordering Kanban. 
D) It does not use poka yoke or 5S practices. 
A) It is particularly well suited for making irregularly used parts and customized "specials." 
B) It is a "push system," with orders pushed out in anticipation of future requirements. 
C) Each container has either a withdrawal or production-ordering Kanban. 
D) It does not use poka yoke or 5S practices.

Question 18

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

Accepted Answer

A) True 
 B)False

Question 19

JIT II 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

A) True 
 B)False

Question 20

Often in value stream mapping,analysts must rely on process information from shop floor workers rather than direct observation in an effort to quickly develop a work plan and accelerate implementing the improved process.

Accepted Answer

A) True 
 B)False

Exam 6: Lean Systems

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

Five S practices can enable workers to visually see everything differently,prioritize tasks,and achieve a greater degree of focus.

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

The list of five S practices includes ________,________,________,________ and ________.

The ________ method activates production of a service or item based on customer demand.

Companies using lean systems generally have:

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?

Explain the meaning of the term takt time,and use a numerical example to illustrate.

There are many requirements for the successful implementation of the lean system of production.Which one of the following is not such a requirement?

A plant's manufacturing process has a takt time of 72 seconds per unit.This results in a process output of how many units per hour?

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.

Some Kanban systems are set up without Kanban cards,and use the material containers or open spaces in a work area to withdraw materials.

Implementing a lean system:

In a ________ system based on other Kanban signals,an empty space signals a need to fill it.

Lean systems maintain inventory in small lot sizes because small lot sizes:

Which one of the following statements regarding the Toyota production system is BEST?

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

JIT II 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.

Often in value stream mapping,analysts must rely on process information from shop floor workers rather than direct observation in an effort to quickly develop a work plan and accelerate implementing the improved process.

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 list of five S practices includes ,,, and .