Question 1

What are the supply chain implications of the lean system emphasis on close supplier ties?

Accepted Answer

Close supplier ties lead to partnerships with a relatively few number of suppliers in close geographic locations.It helps firms get frequent supplier shipments,have short lead time,on-time scheduled arrival of goods of high quality,with deliveries as often as several times per day.Close cooperation leads to better inventory planning and scheduled deliveries that improve both customer and supplier profit margins.Sometimes,a JIT II system is used with the supplier having a representative in the customer's plant,and this representative is then empowered to plan and schedule the replenishment of materials from the supplier.

Question 2

A ________ is a card used to control the flow of production through a factory.

Accepted Answer

Kanban

Question 3

To complete the current state drawing of a process,a map of the current situation is developed,including such items as material and information flows,process times,setup times,batch sizes,scrap rates,and number of people required.

Accepted Answer

A) True 
 B)False  True

Question 4

The Peeps factory can be described as a three step process consisting of Mixing,Forming,and Packaging.Peeps are made in batches of 1000 and have a daily demand of 75,000 units during what the plant manager likes to call "the Peep season." Mixing has a cycle time of .02 seconds with a setup time of 30 seconds;Forming has a setup time of 24 seconds and a cycle time of .03 seconds,and Packaging has a setup time of 15 seconds with a cycle time of .04 seconds.Each process step is handled by one operator,who is available for 8 hours a day.What is the process bottleneck if each process step is assumed to have 100% uptime?

Accepted Answer

The answer of The Peeps factory can be described as...

Question 5

Use the data in Scenario 6.1 to determine the batch size necessary to restrict overall process capacity to 10 units per hour.

Accepted Answer

A)  200 units
B)  220 units
C)  240 units
D)  260 units

Question 6

In lean systems,if a defective product is found,which of the following is generally NOT done?

Accepted Answer

A)  The production line is stopped.
B)  The defective unit is passed on to the next workstation.
C)  The defective unit is returned to the worker responsible for creating the defect.
D)  The production line is made aware of the problem without necessarily stopping the line.

Question 7

Just-in-time (JIT)systems rely on inspectors to inspect quality into the product.

Accepted Answer

A) True 
 B)False

Question 8

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

Accepted Answer

A) True 
 B)False

Question 9

With a batch size of 300 units,what is the per unit processing time for Process C?

Accepted Answer

A)  5 minutes 12 seconds
B)  5 minutes 48 seconds
C)  6 minutes
D)  5 minutes 30 seconds

Question 10

Just-in-time (JIT)systems need close relationships with suppliers.

Accepted Answer

A) True 
 B)False

Question 11

________ is a qualitative lean tool for eliminating waste that involves current state and future state drawings,and an implementation plan.

Accepted Answer

The answer of ________ is a qualitative lean tool for...

Question 12

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

Accepted Answer

A) True 
 B)False

Question 13

Items to be assembled that fit together only the proper way are an example of:

Accepted Answer

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

Question 14

All improvements to the Toyota Production System must be made using the ________ method.

Accepted Answer

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

Question 15

In Scenario 6.1,what does the triangle between Process A and Process B represent?

Accepted Answer

A)  WIP
B)  takt
C)  OWMM
D)  kanban

Question 16

Preventive maintenance is typically given very low priority in just-in-time systems.

Accepted Answer

A) True 
 B)False

Question 17

One big advantage of lean systems is that they can usually be put in place without any major changes to existing layouts.

Accepted Answer

A) True 
 B)False

Question 18

Which of the following is a process consideration in the implementation of a lean system?

Accepted Answer

A)  Firms might have to change existing layouts.
B)  Workstations typically will have to be moved farther apart.
C)  A contract with strict job classifications will have to be adopted.
D)  Plant access by rail will become necessary.

Question 19

List and briefly define the eight types of waste (or muda)that often occur in firms which must be eliminated in implementing lean systems.

Accepted Answer

The answer of List and briefly define the eight types...

Question 20

Weeding out unnecessary items,neatly arranging what's left,and cleaning the work area are components of:

Accepted Answer

A)  a Kanban system.
B)  a constraint management system.
C)  mixed-model assembly.
D)  a 5S program.

Exam 6: Lean Systems

What are the supply chain implications of the lean system emphasis on close supplier ties?

A ________ is a card used to control the flow of production through a factory.

To complete the current state drawing of a process,a map of the current situation is developed,including such items as material and information flows,process times,setup times,batch sizes,scrap rates,and number of people required.

Use the data in Scenario 6.1 to determine the batch size necessary to restrict overall process capacity to 10 units per hour.

In lean systems,if a defective product is found,which of the following is generally NOT done?

Just-in-time (JIT)systems rely on inspectors to inspect quality into the product.

Quality at the source is a philosophy whereby defects are caught and corrected where they are created.

With a batch size of 300 units,what is the per unit processing time for Process C?

Just-in-time (JIT)systems need close relationships with suppliers.

________ is a qualitative lean tool for eliminating waste that involves current state and future state drawings,and an implementation plan.

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

Items to be assembled that fit together only the proper way are an example of:

All improvements to the Toyota Production System must be made using the ________ method.

In Scenario 6.1,what does the triangle between Process A and Process B represent?

Preventive maintenance is typically given very low priority in just-in-time systems.

One big advantage of lean systems is that they can usually be put in place without any major changes to existing layouts.

Which of the following is a process consideration in the implementation of a lean system?

List and briefly define the eight types of waste (or muda)that often occur in firms which must be eliminated in implementing lean systems.

Weeding out unnecessary items,neatly arranging what's left,and cleaning the work area are components of: