Ch 12 Master

Level production requires a stable schedule that requires which of the following: 1. level scheduling 2. freeze windows 3. over utilization of capacity

1 and 2

When considering a lean supply chain, which of the following components can have a lean focus? 1. Suppliers 2. Warehousing 3. Managers

1,2

Uncertainty regarding services can arise from which of the following? 1. Task times 2. Demand 3. Customer's role in production

1,2,3

What type of inventory is impacted by lean production? 1. Raw materials 2. Work-in-process 3. Finished goods

1,2,3

Uncertainty regarding services operations can arise from which of the following?

- uncertainty in task time - uncertainty in demand - customers' production roles

Lean supply chains design principles can be divided into three major categories. The following components are part of lean production schedules...

- uniform plan loading - kanban production control system - determination of number of Kansans needed - minimized setup times

In the textbook Toyota's Fujio Cho identified which of the following types of waste to be eliminated? A. Excess quality B. Motion C. Excess capacity D. Underproduction E. Excess demand

Motion

When determining the size of a kanban, which of the following do you need to consider? 1. Expected demand 2. Safety stock 3. Size of container

All of them

The term "freeze window" refers to the practice of building quality into the process and not identifying quality by inspection.

False

True or False: When comparing service processes and manufacturing, the same sources of variation cause waste.

False

True or false: When comparing service processes and manufacturing, the same sources of variation cause waste.

False

What term is used to describe a philosophy that focuses on continuous improvement?

Kaizen

____ events are specific short-term projects designed to implement changes to a process.

Kaizen

True or false: Just-in-time manufacturing helps to expose problems otherwise hidden by excess inventories and staff.

True

True or false: Producing more than the required amount is considered waste in lean production.

True

Uniform plant loading is a process of smoothing the production activity flow to dampen the reaction waves that normally occur in response to schedule variations.

True

Value stream mapping is used to identify all of the value-adding as well as non-value-adding processes that materials are subjected to within a plant.

True

Value stream mapping is used to visualize product flows through various processing steps.

True

All of the following are types of waste in a lean process except:

Underproduction

What is a special type of flowcharting tool that is used in lean processes?

Value stream mapping

What type of activities transform materials and information into something the customer wants?

Value-adding

What type of activities transform materials and information into something the customer wants?

Value-adding activities

Lean production requires that activities be __________________ to achieve production using minimal inventories.

integrated

In setting up a kanban control system and you need to determine the number of kanban card sets needed. If the expected demand during lead time is 50 per hour, the safety stock is 20% of the demand during lead time, the container size is 4. If the lead time to replenish an order is 2 hours, what number of kanban card sets is needed?

30

You have been called in as a consultant to set up a Kanban control system. The first thing you do is to determine the number of Kanban card sets needed. Your research shows that the expected demand during lead time for a particular component is 1,200 per hour. You estimate the safety stock should be set at 5% of the demand during lead time. The tote trays used as containers can hold 2 units of stock and the lead time to replenish an order is 10 hours. Which of the following is the number of Kanban card sets necessary to support this situation? A. 5,000 B. 5,500 C. 6,300 D. 6,500 E. 7,000

6,300

From which company did lean evolve?

Toyota

Who typically performs preventative maintenance?

operators

Waste reduction is the ______________ of the value-adding activities and the _____________ of non-value-adding activities that are part of the value stream.

optimization; elimination

Value stream mapping displays activities such as

percent uptime. lot size. cycle time. changeover time.

The uniqueness of service delivery leads to which source of variation?

uncertainty in task times

When production flow is smoothed to dampen the schedule variation, we call this

uniform plant loading

When production flow is smoothed to dampen the schedule variation, we call this...

uniform plant loading

When production flow is smoothed to dampen the schedule variation, we call this_____

uniform plant loading

What term describes the value-adding and non-value-adding activities required to design, order and provide a product or service?

value stream

Lean production requires that activities be _______ to achieve production using minimal inventories.

integrated

In which type of operations does lean production work best?

- standardized - repeatable

With regard to lean production, the time between two identical units being completed on the line is called what?

Cycle time

Firms in Japan tend to have short-term relationships with their suppliers and customers.

False

Group technology includes the set of psychological tests and training exercises given to group workers to insure a high level of teamwork.

False

Kanban means "symbol" or "box" in Japanese.

False

Lean production makes implementing green strategies in manufacturing processes more difficult.

False

Lean production replaced JIT in the 1990s because JIT did not address the problem of reducing waste.

False

Lean production requires a "push & pull" system of inventory replenishment.

False

One of the few lean techniques that does not work well in service firms is demand-pull scheduling.

False

T/F A kanban system produces zero inventory.

False

Name Fujio Cho's seven prominent types of waste to be eliminated

(1.) Waste from overproduction; (2.) Waste of waiting time; (3.) Transportation waste; (4.) Inventory waste; (5.) Processing waste; (6.) Waste of motion; (7.) Waste from product defects

The uniqueness of service delivery leads to which of the following sources of variation?

- Customers' production roles - Uncertainty in demand - Uncertainty in task times

Lean supply chains design principles can be divided into three major categories. Which of the following components are part of lean supply chains?

- building a lean supply chain - specialized plants - collaboration with suppliers

Which of the following is a signal that could be used in a kanban system?

- containers - cards - golf balls

Value stream mapping (VSM) is a two-part process. What are those parts?

- current state - future state

Lean production uses a pull system. To enable this pull process to work smoothly, lean production demands what?

- fairly predictable demand for the end product - strong vendor relations - having levels of quality at each stage of the process

Lean production requires a stable schedule that is accomplished by____?

- freeze windows - level scheduling

Lean production uses a pull system. To enable this pull process to work smoothly, lean production demands what?

- high levels of quality at each stage of the process - strong vendor relations - fairly predictable demand for the end product

Value stream mapping (VSM) is used to visualize what?

- information flows - product flows

When considering a lean supply chain, which of the following components can have a lean focus?

- lean suppliers - lean procurement - lean manufacturing - lean warehousing - lean logistic - lean customers

value stream mapping (VSM) is a two part process. What are those two parts?

1. current state 2. future state

When considering a lean supply chain, what components can have a lean focus?

1. customers 2. warehousing 3. supplies 4. logistics 5. manufacturing 6. procurement

Value stream mapping (VSM) is used to visualize what?

1. information flows 2. product flows

When determining the size of a kanban, which of the following do you need to consider?

1. safety stock 2. size of the container 3. expected demand

uncertainty regarding services operations can arise from the following:

1. uncertainty in task times 2. customers' production roles 3. uncertainty in demand

What type of inventory is impacted by lean production?

1. work-in process 2. finished goods 3. raw materials

In setting up a Kanban control system you need to determine the number of Kanban card sets needed. If the expected demand during lead time is 50 per hour, the safety stock is 20% of the demand during lead time, the container size is 4. If the lead time to replenish an order is 8 hours, what number of Kanban card sets is needed? A. 60 B. 80 C. 90 D. 120 E. 150

120

In setting up a kanban control system you need to determine the number of kanban card sets needed. If the expected demand during lead time is 24 per hour, safety stock is 10% of the demand during lead time, the container size is 5. If the lead time to replenish an order is 5 hours, what number of kanban card sets is needed?

27

n setting up a Kanban control system you need to determine the number of Kanban card sets needed. If the expected demand during lead time is 25 per hour, the safety stock is 20% of the demand during lead time, the container size is 5, and the lead time to replenish an order is 5 hours, what is the number of Kanban card sets needed? A. 5 B. 20 C. 27 D. 30 E. 34

30

You have been called in as a consultant to set up a Kanban control system. The first thing to do is to determine the number of Kanban card sets needed. Your research shows that the expected demand during lead time for a particular component is 150 per hour. You estimate the safety stock should be set at 25% of the demand during lead time. The tote trays used as containers can hold 8 units of stock and the lead time it takes to replenish an order is 2 hours. Which of the following is the number of Kanban card sets necessary to support this situation? A. 42 B. 47 C. 68 D. 89 E. 94

47

Which of the following are related to lean production? A. A philosophy of waste elimination B. Lean consumption C. Never running out of inventory D. The Wahei-Subaru method E. Full use of capacity

A philosophy of waste elimination

Uncertainty regarding services can arise from which of the following? 1. task times 2. demand 3. customer's production role

All of them

An activity where the parts that go into each unit of a product are periodically removed from inventory and accounted for based on the number of units produced. is called which of the following? A. Frozen window B. Backflush C. Level schedule D. Group Technology E. Kanban

Backflush

Which of the following is a lean production technique that has been successfully applied in service firms? A. Decision trees B. Leveling the facility load C. Linear programming D. Fully utilizing capacity E. Backflushing

Backflushing

In lean production, what is defined as something for which the customer is willing to pay?

Customer value

Value stream mapping is a two-part process that details what?

Current and future states

T/F Waste reduction refers only to the elimination of non-value adding activities that are part of the value stream.

False

Which of the following is not an example of process waste?

Defect-free products

In designing a lean production facility layout a designer should do which of the following? A. Design for work flow balance B. Locate flexible workstations off line C. Link operations through a push system D. Balance capacity using job shop analysis E. Always keep operations on a single floor of the factory

Design for work flow balance

To develop a lean manufacturing system a firm might do which of the following? A. Eliminate anything that does not add value for the customer B. Standardize product configurations C. Process design with product design D. Adopt a kaizen philosophy E. Implement top-down management controls

Eliminate anything that does not add value for the customer

Uniform plant loading is where you schedule production with different amounts of the same product each day of the week to permit variation to meet changing demand requirements.

FALSE (Uniform plant loading is) building the same mix of products every day in small quantities. Thus, a total mix is always available to respond to variations in demand.

JIT manufacturing forces a firm to work with a lower water level despite safety hazards

FALSE Exhibit 12.6 presents water levels as an allegory for inventory levels. Lower water levels expose potential problems (rocks). Using JIT reduces inventory to a minimum level. Thus, "JIT manufacturing exposes problems otherwise hidden by excess inventories and staff." None of this has to do with actual water or safety hazards.

JIT is typically applied to non-repetitive manufacturing.

FALSE JIT is typically applied to repetitive manufacturing, which is when the same or similar items are made one after another.

JIT production means that we produce the product before it is required so the customer does not wait for the product.

FALSE Just-in-time means producing what is needed when needed and no more.

Applying lean concepts to logistics is difficult unless either the manufacturer or the customer owns the logistics activities.

FALSE Lean concepts can be applied to the functions associated with the movement of material through the system. Some of the key areas include optimized mode selection and pooling orders; combined multi-stop truckloads; optimized routing; cross docking; import/export transportation processes; and backhaul minimization.

In the textbook the expression "quality at the source" means that we need to purchase the best quality a supplier or vendor can provide.

FALSE Quality at the source means do it right the first time and, when something goes wrong, stop the process or assembly line immediately.

The goal of JIT production is to drive all inventory queues lower.

FALSE The goal (of JIT) is to drive all inventory queues to zero, thus minimizing inventory investment and shortening lead times.

Subcontractor networks are not very important in Japanese manufacturing.

FALSE Toyota relies heavily on subcontractor networks.

A principle of value stream mapping is to concentrate on speeding up value-added operations.

FALSE Value stream mapping (VSM) is a special type of flowcharting tool that is valuable for the development of lean processes. The technique is used to visualize product flows through various processing steps.

"Kanban Squares" is an educational game played in Kanban training sessions.

False

A kaizen burst is an overfilled kanban container.

False

Using the formula in the textbook the only parameters we need to determine the number of Kanban card sets is the average number of units demanded over some time period, the container size, and the safety stock.

False

Value stream mapping involves materials, not information.

False

Applying lean concepts in manufacturing balances increases in cost with quality improvement

False Applying lean concepts in manufacturing typically presents the greatest opportunities for cost reduction and quality improvement.

True or false: When comparing service processes and manufacturing, the same sources of variation cause waste.

False. many sources of variation

Which of the following is a lean production technique that is not reported in the textbook to have been successfully applied in service firms? A. Organize problem-solving groups B. Upgrade housekeeping C. Upgrade quality D. Freeze windows E. Eliminate unnecessary activities

Freeze Windows

Which of the following is NOT a concept related to lean network design?

Generalized plants

What term describes a philosophy in which similar parts are grouped into families and processes to make the parts are arranged into manufacturing cells?

Group technology

To implement lean production schedules a firm would do which of the following? A. Have excess capacity B. Force demand C. Hire a consultant D. Bottom-up management E. Implement kanban groups

Have excess capacity

Which of the following statements holds true for Kanban production control systems? A. The authority to produce or supply additional parts comes from upstream operations B. In a paperless control system, containers can be used instead of cards C. The cards or containers make up the Kanban push system D. They require substantial quantitative analysis prior to implementation E. They have not been successful outside of Japan and the United States

In a paperless control system, containers can be used instead of cards

What information is shown in a value stream map?

Information flow Product flow

What information is shown on a value stream map?

Information flow and Product flow

When designing a lean layout, the system designer must consider how each type of logistics systems tie to the layout?

Internal and external

Which of the following is not a lean technique applied to service companies?

Introduce push scheduling

What served as the basis for lean thinking?

JIT

What type of production only produces what is needed when it is needed?

JIT

What term represents a signaling device to control production?

Kanban

Which of the following are elements that address elimination of waste under lean production? A. Production ahead of demand B. Group plant loading technology C. Kanban production control system D. Minimized run times E. Full capacity utilization

Kanban production control system

When space is marked on the floor to identify where products should be stored is an example of which type of kanban signal?

Kanban squares

Which of the following would NOT be considered acceptable in the Toyota Production System?

Laying off employees when business is slow

What type of production focuses on eliminating as much waste as possible?

Lean

Which of the following is not listed in the textbook as a component of a lean supply chain? A. Lean customers B. Lean Management C. Lean logistics D. Lean warehousing E. Lean procurement

Lean Management

An operation that is repeatable and standardized is a good candidate for:

Lean Production and Six Sigma

What are the three sets of principles related to supply chain design?

Lean concepts Lean supply chain Lean production schedules

Which supply chain principles refer to internal production processes?

Lean production schedules Lean concepts

When implementing a lean production system a stabilized schedule is achieved using which of the following? A. Level scheduling B. Demand pull C. Freeze window D. Reduced lot sizes E. Bottom-round management

Level scheduling

In which part of a lean supply chain would you expect to see lean concepts applied to the movement of materials through the system?

Logistics

Which of the following is NOT a benefit of lean supply chains?

Lower employee wages

Which of the following is not a benefit of lean supply chains?

Lower employee wages

In implementing a lean production system you should work with suppliers to do which of the following? A. Calculate lead times B. Quality circles C. Freeze windows D. Make frequent deliveries E. Achieve bottom-round management

Make frequent deliveries

Who typically performs preventative maintenance?

Operators

In the textbook Toyota's Fujio Cho identified which of the following types of waste to be eliminated? A. Excess quality B. Overproduction C. Underproduction D. Environmental E. Over-thinking

Overproduction Fujio Cho identifies seven prominent types of waste to be eliminated from the supply chain: (1) waste from overproduction, (2) waste of waiting time, (3) transportation waste, (4) inventory waste, (5) processing waste, (6) waste of motion, and (7) waste from product defects.

When conducting preventative maintenance, how often should inspection and repair be planned?

Periodically

In a lean supply chain, which component includes automation for sourcing, bidding, and auctions?

Procurement

In the textbook Toyota's Fujio Cho identified which of the following types of waste to be eliminated? A. Underproduction B. Excess quality C. Preventive maintenance D. Product defects E. Kaizen

Product defects

Kanban production control and minimized setup times are part of the Lean _____ ______ principle.

Production Schedules

Which of the following address elimination of waste under lean production? A. Info-matic warehouse networks B. Outsourced housekeeping C. Quality at the source D. Backflush E. Bottom-round management

Quality at the source Quality at the source means do it right the first time and, when something goes wrong, stop the process or assembly line immediately.

In implementing a lean production system you should work with suppliers to do which of the following? A. Open facilities near your factory B. Focus workstation capacities C. Backflush D. Provide quality at the source E. Reduce lead times

Reduce lead times

To implement a flow process in developing a lean system a firm might do which of the following? A. Improve capacity utilization B. Build product in anticipation of demand C. Reduce setup/changeover time D. Eliminate some fixed costs E. Implement groupware

Reduce setup/changeover time

Group technology (GT) is credited with which of the following benefits? A. Reducing waiting time between process operations B. Improving inventory discipline C. Reducing required workforce skills D. Improved labor relations E. Improved small group functioning

Reducing waiting time between process operations

In the Toyota Production System, ____ for people is exemplified by providing opportunities and job security for employees.

Respect

An operation that is repeatable and standardized is a good candidate for

Six Sigma. lean production.

With regard to lean production, the time between two identical units being completed on the line is called what?

cycle time

Which characteristics make an operation particularly well-suited to lean production and Six Sigma?

Standardized, Repeatable

Imagine comparing a manufacturing operation using regular lot-sizing and the same operation with a Kanban/lean production approach. What would be your expectations of the difference between the total cost (i.e., inventory holding costs + setup/ordering costs) of each? A. Inventory holding cost will increase non-linearly with inventory B. Total costs will be lower for the regular lot-size operation C. Total costs will be lower for the Kanban/lean production operation D. The order quantity will be larger for the Kanban/lean production approach E. As long as the total quantity is the same, total costs will be the same

Total costs will be lower for the Kanban/lean production operation

"Quality at the source" requires factory workers to become their own inspectors.

True

A Kanban control system uses a signaling device to regulate JIT flows.

True

A kaizen burst is a symbol on a value stream map.

True

Automation is a key to lean procurement.

True

Company unions in Japan exist to foster a cooperative relationship with management.

True

Group technology is a philosophy wherein similar parts are grouped together and the processes required to make the parts are arranged as a work cell.

True

Henry Ford used JIT concepts as he streamlined his moving assembly lines to make automobiles in the early 1900's.

True

In Japanese manufacturing automation and robotics are used extensively to perform dull or routine jobs so employees are free to focus on important improvement tasks.

True

Lean production is a management philosophy and a pull system throughout the plant.

True

Lean production is an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials, work in process, and finished goods.

True

One of the aims of value stream mapping to eliminate waste in a process.

True

One of the many lean techniques that have been successfully applied in service firms is leveling facility load.

True

One of the many lean techniques that have been successfully applied in service firms is the eliminating of unnecessary activities.

True

One of the many lean techniques that have been successfully applied in service firms is the upgrading of housekeeping.

True

One of the many lean techniques that have been successfully applied in service firms is the upgrading of quality.

True

Preventive maintenance is emphasized in lean production to ensure that flows are not interrupted by downtime or malfunctioning equipment.

True

Respect for people is a key to Toyota's improvement ideas in manufacturing.

True

T/F A lean layout requires a balanced work flow.

True

T/F Lean production uses a pull system for production.

True

True or False: A lean layout requires a balanced workflow.

True

True or False: Value stream includes both value-added and non-value-added activities.

True

What is defined as anything that does not add value from the customer's perspective?

Waste

What is not an example of process waste?

decent free products

What type of inventory is impacted by lean production? 1. Raw materials 2. Work-in-process 3. Finished goods

all

When you remove the number of parts used in production to adjust on-hand inventory balances, you are conducting a ___?

back flush

When you remove the number of component parts based on the number of units produced, you are conducting a

backflush

When you remove the number of parts used in production to adjust on-hand inventory balances, you are conducting a ___

backflush

To create a lean process, a full understanding of the __________is required.

business

Lean ______ utilizes group technology, quality at the source, and JIT production to support development of a lean supply chain.

concepts

Value stream mapping is used to show both the ____ state of a process as well as a possible ____ state.

current; future

Value stream mapping is used to show both the __________state of a process as well as a possible ______________ state.

current; future

In lean production, what is defined as something for which the customer is willing to pay?

customer value

Which of the following is NOT an example of process waste?

defect free products

Which of the following is not an example of process waste?

defect free products

The following is not a lean technique applied to service companies:

eliminate housekeeping

True or false: Waste reduction refers only to the elimination of non-value-adding activities that are part of the value stream.

false

True or false: when comparing service processes and manufacturing, the same sources of variation cause waste.

false

True or false: when utilizing a quality at the source approach, employees do not have the authority to stop the process if there is a problem.

false

True or false: a kanban system produces zero inventory

false; it controls the amount of material that can be in process at a time -- the number of containers of each item.

In a system using group technology, works must be ____ to run several machines and processes.

flexible

In a system using group technology, workers must be ___________ to run several machines and processes.

flexible enough

What term refers to the period of time during which the schedule is fixed and no further changes are possible?

freeze window

Which of the following is not a concept related to lean network design?

generalized plants

_____ is not a concept related to lean network design?

generalized plants

What term describes a philosophy in which similar parts are arranged into families and processes to make parts by manufacturing cells?

group technology

Lean principles throughout the supply chain can primarily be seen in

improved responsiveness to the customer.

Lean production requires that activities be ______ to achieve production using minimal inventories

integrated

The acronym JIT stands for ____.

just-in-time

What type of production only produces what is needed when it is needed?

just-in-time (JIT)

___________ bursts are specific, short-term projects designed to implement changes to a process.

kaizen

In a _____ pull system, downstream operations provide the authorization for upstream production to occur.

kanban

When space is marked on the floor to identify where products should be stored is an example of which type of kanban signal?

kanban squares

Which of the following would NOT be considered acceptable in the Toyota Production System? 1) providing employees with promotion opportunities 2) laying off employees when business is slow 3) training employees to learn new skills 4) working with employees to solve disputes

laying off employees when business is slow

The Toyota Production System is the benchmark for _______ manufacturing.

lean

What type of production focuses on eliminating as much waste as possible?

lean

Which of the following is not a category that applies to lean design principles?

lean transportation

When comparing service processes to manufacturing processes, one would say that they are ____ controllable.

less

When comparing service processes to manufacturing processes, one would say that they are _____ controllable.

less

When comparing service processes to manufacturing processes, one would say that they are _________ controllable.

less

What type of schedule requires material to be pulled into final assembly in a uniform pattern?

level

In which part of a lean supply chain would you expect to see lean concepts applied to the movement of materials through the system? 1) Customers 2) Manufacturing 3) Logistics 4) Warehousing

logistics

Reduced setup times are important because they lead to reductions in ____ size.

lot

Which of the following is not a benefit of lean supply chains? 1) Improved customer responsiveness 2) Lower employee wages 3) Reduced inventory levels 4) Reduced obsolescence costs

lower employee wages

In a lean production system we expect to see which of the following? A. No extra inventory B. Extra inventory of critical parts held "just-in-case" C. More parts and fewer standardized product configurations D. Managers being held responsible for quality of the work turned out E. Closer management-labor relationships

no extra inventory

Waste reduction is the _____ of the value-adding activities and the ____ of non-value adding activities that are part of the value stream.

optimization; elimination

Waste reduction is the _____ of the value-adding activities and the ______ of non-value-adding activities that are part of the value system.

optimization; elimination

Waste reduction is the ______________ of the value-adding activities and the _____________ of non-value-adding activities that are part of the value stream. 1) elimination; elimination 2) elimination; optimization 3) optimization; optimization 4) optimization; elimination

optimization; elimination

When conducting preventative maintenance, how often should inspection and repair be planned?

periodically

In both services and manufacturing, waste associated with defects can be reduced by improving _____.

quality

A term used for the philosophy of making factory workers personally responsible for the quality of their output is

quality at the source

A term used for the philosophy of making factory workers personally responsible for the quality of their output is ____

quality at the source

Which characteristics make an operation particularly well-suited to lean production and Six Sigma? (can choose more than one) 1. uncertain 2. standardized 3. chaotic 4. repeatable

repeatable and standardized operations

the following is not a type of waste...

respect for people

The two core philosophies of the Toyota Production System are

respect for people. elimination of waste.

The following is not considered in lead time when calculating the number of Kansans needed?

shipping time from the supplier

When designing a lean supply chain, what type of approach should be taken to integrate partners?

systems

Customers play a role in production with services because

they typically have to give information to begin the service process

Customers play a role in production with services because

they typically have to provide information to begin the service process.

The benchmark for lean manufacturing is known as the

toyota production system

The benchmark for lean manufacturing is known as the...

toyota production system

Group technology cells help to eliminate movement and queue (waiting) time between operations.

true

True or false: Lean production uses a pull system for production.

true

True or false: Value stream includes both value-added and non-value-added activities.

true

True or false: a lean layout requires a balanced work flow

true

What term describes the value-adding and non-value-adding activities required to design, order and provide a product or service? 1) Product mapping 2) Flowcharting 3) Project management 4) Value stream

value stream

What is a special type of flowchart tool that is used in lean processes?

value stream mapping

What is a special type of flowcharting tool that is used in lean processes?

value stream mapping

What is defined as anything that does not add value from the customer's perspective?

waste