scm chapter 8

lean systems

approach is a philosophy that emphasizes the minimization of the amount of all resources used in the various activities of an enterprise.

Kanban scheduling

is a scheduling system that builds output in response to actual customer demand.

Poka-yoke

is an emphasis on redesigning processes in such a way as to make mistakes either impossible or immediately apparent to the worker.

Identify the examples of visual controls. (Check all that apply.)

- Andon boards - Lighting systems - SPC (statistical process control) charts

visual control

makes current performance and potential problems immediately visually apparent

sort straighten scrub systematize standardize

seiri seition seiso seiketsu shitsuke

Identify the benefits of the application of the lean systems approach across the supply chain. (Check all that apply.)

- Application of lean approach leads to improved quality, reduced costs, and improved customer service. - Suppliers and customers better understand each other's needs and capabilities. - In stable environments, lean can enhance the performance of the supply chain.

Identify the symptoms of an overproduction waste. (Check all that apply.)

- Extra inventory - Utilization of excessive floor space - Complex information management - Unbalanced material flow

Operational/technological social natural/hazard economy/competition legal/political

- Forecast errors, capacity constraints, and IT disruptions - Labor strikes and sabotage - Fire, flood, monsoon, and earthquake - Interest rate fluctuations and bankruptcy of supply partners - Lawsuits, wars, border customs, and regulations

Identify the methods by which lean systems can lower the break-even production quantity of a firm. (Check all that apply.)

- Increasing the contribution margin - Reducing fixed overhead costs

Identify the benefits of lean systems. (Check all that apply.)

- Lean systems lower the variable production costs associated with labor, materials, and energy. - lean systems raise the unit profitability of products. - A firm can significantly lower its break-even production quantity.

Identify the different terms used for poka-yoke. (Check all that apply.)

- Mistake proofing - Fail-safing

Identify the important principles that are used to achieve the objectives and principles of lean systems. (Check all that apply.)

- Precisely specify value for each specific product. - Identify the value stream for each product. - Let the customer pull value from the producer. - Pursue perfection. - Make value flow without interruptions.

manage with data waste is a sympton goals are to be met standardization is fundamental to performance improvement process orientaion

- Problems and solutions are identified, solved, and evaluated with data. - Inventory and other visible forms of waste are never attacked directly. Rather, they are seen as the results of problems elsewhere. - Managers set realistic, achievable goals. The expectation is that everyone will meet their goals. - It highlights variation and abnormalities and simplifies problem solving. - If the outcomes (the level of quality, the cost, the lead time) are undesirable, then the process is changed. Lean involves attaining superior behavior by identifying the critical processes and changing them.

Waste of overproduction waste of waiting processing waste waste from product defects Waste of motion

- Processing more units than necessary - Resources wasted waiting for work - Excessive or unnecessary operations - Waste due to unnecessary scrap, rework, or correction - Unnecessary or excessive resource activity

sort straighten scrub systematize standardize

- Red tag suspected unnecessary items. After a monitoring period, throw out unnecessary items. - Put everything in an orderly fashion so that it can be located. - Clean everything and eliminate the sources of dirt. - Make cleaning and checking routine. Set the standard, train and maintain. - Continuously improve processes and use visual control through performance boards, checklists, and graphs.

Identify the objectives and principles of lean systems. (Check all that apply.)

- Reinforce the occupational development of workers. - Only produce products that customers want. - Only produce products as quickly as customers want them. - Produce products with the features that customers want. - Produce products with no waste of labor, materials, or equipment. - Produce products with perfect quality.

Separate internal and external setups Convert internal setups to external setups Streamline all activities in a setup

- Segregate setup procedures that occur while an equipment sits idle from the setup activities that workers complete while the equipment operates. - Examine the flow process chart and develop a new process. - Eliminate the activities performed to make adjustments, calibrations, elaborate positioning, unnecessary tightening, or trial runs.

Identify the different terms used to describe lean systems. (Check all that apply.)

- Stockless production - Just-in-time manufacturing - Zero inventories - Toyota Production System - Lean production

Identify the lean systems tools that are used for operational scheduling and control. (Check all that apply.)

- TAKT time flow balancing - Setup reduction - Mixed model scheduling - Kanban (pull) scheduling - Statistical process control - Visual control

Precisely specify value for each specific product Identify the value stream for each product Make value flow without interruptions Let the customer pull value from the producer Pursue perfection

- The final consumer ultimately determines the value of a product or service. - A firm must clearly understand and link together all of the activities involved in product development, order processing, production, and delivery. - The movements of materials and information in value streams should be swift and even. - Activities in operating processes should be initiated by actual customer demands not by schedules that are based on forecasts. - Continuous improvement is always possible.

Identify the lean systems tools that are used for development of facilities and resources. (Check all that apply.)

- Total productive maintenance - Group technology - Focused factories

waiting transportation processing inventory motion Product defects

- Underutilization of resources, reduced productivity, increase in investment, and idle equipment - Extra handling equipment, large storage areas, overstaffing, damaged product, and extra paperwork and hand-offs - Extra equipment, longer lead time, reduced productivity, extra material movement, sorting, testing, and inspection, and inappropriate use of resources - Complex tracking systems, extra storage and handling, extra rework, paperwork, and stagnated information flow - Reduced productivity, large reach, excess handling, and reduced quality - Rework, repairs, and scrap, customer returns, loss of customer confidence, and hazardous waste generation

Identify the prescriptions that the application of lean principles to supply chain relationships leads to. (Check all that apply.)

- Work with suppliers and not against them. - Buy to achieve the lowest total cost. - Treat problems as a symptom and focus on the factors that contributed to the emergence of that problem. - Minimize the number of suppliers. - Keep distances between partners short.

- The design of training programs needs to be driven by lean objectives. - The lean approach requires tight coordination of marketing, sales, and operations to increase communication and decrease order processing lead times. - Self-motivated employees who have a strong interest in solving problems through process innovation must be hired.

Identify the true statements about the application of lean systems within a firm. (Check all that apply.)

Identify the principle of lean systems that places a strong value on viewing and organizing the activities involved in product development, order processing, production, and delivery as processes within an overall system and mapping these processes in order to identify value-adding and non-value-adding steps.

Identify the value stream for each product.

Define single minute exchange of dies.

It is a systematic three-stage approach procedure for reducing long setups.

Define andons.

It is the use of visual indicator system such as flashing lights to help management access current performance and identify the location of problems.

Identify the reasons why employees are viewed as critical resources for success in the lean systems philosophy. (Check all that apply.)

Source of flexibility Power in their hands Working in teams Acceptance

false

True or false: Every operational setting and business sector implements the same level of lean systems in application and practice.

a push scheduling

activities are initiated and products are moved according to a schedule, irrespective of whether or not a customer demands it.

A manager making use of the Kanban scheduling authorizes production or withdrawal based on the

actual customer demand

lean system culture

is the culture that is present in lean systems and that places a high value on respect for people in the system.

Stop-and-fix system

is the practice by which an operator should stop the process and immediately fix problems rather than allowing it to continue making poor-quality output. Kaizen Event

Quality at the source

is the practice of eliminating defects at their root cause origination points.

setup reduction

is the process used to reduce setup and changeover times with the goal of making the output of smaller batches more efficient.