Chapter 16 - lean systems
In lean production, waste is defined as anything that does not add value to the product. True or false
True
A workstation's output is 200 bottles of wine per hour. It takes 45 minutes to receive a withdrawal kanban of corks from the previous workstation. The withdrawal kanban is attached to a container holding 30 corks. The process uses a safety factor of 20 percent. What is the number of withdrawal kanbans needed to support the bottling process? A. 6 B. 3 C. 4 D. 5
A. 6
Takt time is the pace at which production output is A. Equal to demand B. Minimum C. Greater than demand D. Maximum
A. Equal to demand
Which of the following is a drawback of lean production: A. Mass production parts B. Lean production is still evolving C. Reduced inventory often causes stockouts D. Lean production does not have major drawbacks
A. Mass production parts
A work station must produce 400 units an hour. It takes 24 minutes to receive the necessary material for production from the previous workstation. Output is moved between workstations in containers holding 44 units. If the process uses a safety factor of 10%, then the amount of safety stock on average would be A. 6 B. 32 C. 16 D. 8
C. 16
The benefits of lean production include all of the following except reduced A. Cost B. Inventory C. Product variation D. Leadtime
C. Product variation
How many kanbans should circulate between two workstations if demand is 500 units per hour, lead time is 20 minutes, container sizes are 35, and the company uses a safety factor of 5%? A. 8 B. 4 C. 12 D. 5
D. 5
Value stream mapping (VSM) is a tool for A. Improving quality B. Designing manufacturing cells C. Reducing set up times D. Analyzing process flows
D. Analyzing process flows
_______ is a Japanese term that means fool proofing to prevent defects. A. Muda B. Kaizen C. Jidoka D. Pokayoke
D. Poka yoke
Tim Woods helped bring the idea of eliminating waste to the USA from Japan True or False
False
seisou is the 2nd step in 5S ● True or False
False
Match each example to the type of waste it is: Waiting: expecting information to arrive Transportation: moving information excessively Over Processing: doing more work than necessary Defects: reworking mistakes Skills: wanted employee efforts
Waiting: expecting information to arrive Transportation: moving information excessively Over Processing: doing more work than necessary Defects: reworking mistakes Skills: wanted employee efforts
Which of the following is not typically a component of lead time? a) Breakdown time b) Setup time c) Move time d) Wait time
a) Breakdown time
Waste
any activity or task that does not create value
Which of the following is not a basic element of lean production? a) Flexible resources b) Repetitive production c) Small lot production d) Pull systems
b) Repetitive production
Kanban
card system to replenish inventory
TPM
combines maintenance with quality concepts
Over Processing
doing more work than necessary
Jidoka
employee's authority to stop the production line
Waiting
expecting information to arrive
Transportation
moving information excessively
Defects
reworking mistakes
Andon
visual system to signal quality problem
Skills
wanted employee efforts
match each terms with the best definition ● Andon: visual system to signal quality problem ● Waste: any activity or task that does not create value ● Jidoka: employee's authority to stop the production line ● Kanban: card system to replenish inventory ● TPM: combines maintenance with quality concepts
● Andon: visual system to signal quality problem ● Waste: any activity or task that does not create value ● Jidoka: employee's authority to stop the production line ● Kanban: card system to replenish inventory ● TPM: combines maintenance with quality concepts
How does Kanban impact inventory position? A.Reduces inventory resulting in elimination of wasted cost B. Reduces inventory making problems visible C. Increases inventory to prevent stockouts D. Kanban does not have direct impact on inventory
B. Reduces inventory making problems visible
