Week 15 - Lean - Smartbook/Quiz

When lean systems are implemented:

Fixed and variable costs both tend to decrease.

_____ organizes operations systems by grouping together similar customers and then designing and implementing product systems to serve these specific customers.

Focused factory

_____ is an approach to work layout and scheduling that gathers in one location all of the equipment and work skills necessary to complete production of a family of similar products.

Group Technology

Level, mixed-model scheduling is also known as

Heijunka

_____ is a short-term approach to enhancing efficiency that focuses on improving an existing process or an activity within a process.

Kaizen Event

makes current performance and potential problems immediately visually apparent.

Visual Control

Match the types of wastes (given in the left column) with their respective symptoms (given in the right column).

Check photos 12/11

_____ works to identify and prevent all possible equipment breakdowns.

Total productive maintenance

Identify the true statements about total productive maintenance (TPM). (Check all that apply.)

A TPM program requires disciplined adherence to operating procedures and rigorous equipment design and upkeep. In addition to manufacturing equipment, TPM can be applied to computer networks and automated service kiosks. Typical TPM programs emphasize shop floor organization.

Match the activities of a 5-S program (in the left column) with their respective intent (in the right column).

Check photos 12/11

In a lean system, waste is any action that

Does not generate value.

John Jones is a plant manager. He believes his plant is guilty of "waste of overproduction." Which of the following symptoms might he have observed that led to this belief?

Excess Inventory

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

Fail-safing Mistake proofing

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

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

A standard electrical plug fits into an outlet in only one way because one of the two prongs is larger than the other. This ensures that people will insert the plug properly to create a grounded circuit. This is an example of:

Poka-yoke

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

Poka-yoke

Footprinting is an example of which of the following elements of the 5-S program?

Seiton/Straighten/Configure

In lean systems, _____ is aimed at clarifying and documenting the steps in a process so that they are executed exactly the same way every time by every worker.

Standardization

True or false: The essential goal of SPC (statistical process control) is to put controls in place that help ensure the quality of production and give quick notice when unusual events occur that might lead to product or service defects.

True

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

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

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

Working in teams Power in their hands Acceptance Source of flexibility

In _____, activities in the operating processes are initiated by actual customer demands, not by schedules that are based on forecasts.

a pull system

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

a push scheduling

Match the different types of wastes (in the left column) with their respective definitions (in the right column).

Check photos 12/11

Match the important values of lean system culture (in the left column) with their respective descriptions (in the right column).

Check photos 12/11

Match the types of wastes (given in the left column) with their respective root causes (given in the right column).

Check photos 12/11

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

Group technology Focused factories Total productive maintenance

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

Define process analysis/value stream mapping.

It is a graphical technique that helps managers understand material and information flows as a product makes its way through the process.

Define single minute exchange of dies.

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

Identify the true statements about group technology.

It is also called cellular manufacturing. In group technology, part families are created based on the similarities in design features.

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.

Applying lean systems to supply chain relationships has which of the following risks?

It makes the supply chain more vulnerable to performance breakdowns.

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

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

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

Lean System Culture

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

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

_____ is the practice of leveling quantities of different product models produced over a period of time, with the goal of reducing batch sizes and lead times.

Level, mixed model scheduling

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

Lighting systems SPC (statistical process control) charts Andon boards

Match the different focused factories (in the left column) with their respective description (in the right column).

Market focused- Supplying a range of products to customers with similar or complementary demand patterns and value propositions Product focused- Production of products that have similar technological processing requirements

Match the linked steps of level, mixed-model scheduling (in the left column) with their respective description (in the right column).

Mixed modeling - Deciding the method to distribute the production of different products over the workday. Load Leveling - Calculating the average rate of production needed for each item based on the overall TAKT time.

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

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

In lean systems, _____ focuses on eliminating non-value-added activities in a process.

Simplification

_____ uses various statistical tools to analyze the capabilities of a given process and monitor its performance with the goal of flagging potential problems before they occur.

Statistical process control

_____ 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.

Stop-and-fix system

A firm works a 40 hour week to process 4000 customers' orders, but processes only 50 orders per hour. The firm tries to bring up their output rate to 100 orders per hour to meet the customer demand. Which of the following does this scenario illustrate?

TAKT time flow balancing

Identify a scheduling approach aimed at synchronizing the output rate with the rate of customer demand.

TAKT time flow balancing

Which two of the following areas does lean/just-in-time production focus its attention on?

Variance and waste

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

actual customer demand

In the lean systems approach, as a system improves, it should have ____________ inventory on hand.

less

A production kanban authorizes a worker to:

replenish an empty bin