Ch 8 MAR6466 on Final Exam

In our accounting department one of the actions taken by a clerk has been to identify the most frequently used forms and to put them in an area where they can be easily accessed. The other less frequently used forms have been tagged and put in their own separate area. This action likely occurred from the use of which lean tool?

A 5-S program

The purpose of the kanban card is to:

Be a signal from the user authorizing the maker to start producing the required parts.

Which of the following lean principles best communicates the notion of demand synchronization?

Build only as quickly as customers want them.

We have a situation where we have many different processes; high quantities are required to deliver the product's value both on the factory floor and in the customer's use. Which of the following categories of waste in product design have we encountered in this situation?

Complexity

Zanadu Corp. produces several different colors of a product on a single production line. It used to take several hours to switch colors, but now Zanadu has found a way to prepare for changing colors in a few minutes. This was most likely accomplished by:

Converting internal to external setups.

In a lean system, waste is any action that

Does not generate value.

Which of the following is NOT one of the product/process design principles associated with lean/just-in-time production?

Encourage use of unique components.

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.

When lean systems are implemented:

Fixed and variable costs both tend to decrease.

Which of the following most accurately describes the role of quality in a lean/just-in-time manufacturing environment?

High quality is an important waste reduction tool. Reducing defects reduces wasted material and capacity, and reduces the need for safety stocks.

Which of the following two areas does lean/just-in-time production focus its attention on? I. Cost II. Quality III. Variance IV. Waste

III and IV

Which of the following would you NOT expect to find in a company attempting to implement lean/just-in-time production?

Inspections after each piece is produced

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

It makes the supply chain more vulnerable to performance breakdowns.

C-TPAT or Customs-Trade Partnership Against Terrorism is a program designed to manage the flow of orders across borders. It is an example of which of the following risks for lean supply chains?

Legal/political

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

Less

Lean systems applications have found the most acceptance and adoption in:

Manufacturing firms.

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.

Unnecessary automation is an example of which of the following forms of waste?

Process

We observe a man working on a setup. During the process of setting up, the man positions the die at a first position. He then runs through a few pieces to check whether or not they are acceptable. He then repositions the die and repeats the process. What we have observed is which of the following forms of waste?

Processing waste

McGreen Burger Shop sells about two burgers per minute. Although the cook can cook up to 10 burgers per minute, he starts to cook another burger only after the salesperson removes a burger from the ramp. The ramp is large enough to hold only five burgers and keep them warm until a sale is made. This is an example of a:

Pull system.

Johnson Corp. has so strongly embraced the lean philosophy that it wants to apply the approach to all processes in the organization. Doing this may actually have the most severe negative impact on:

Radical product innovation.

Most of the tools and techniques used in lean systems seek to:

Reduce variability from the system.

A production kanban authorizes a worker to:

Replenish an empty bin.

Tools at the point of use is an example of which of the following elements of the 5-S program?

Seiton/Straighten/Configure

Achieving the goal of producing at the output rate which matches the rate of customer demand is the goal of:

Takt time flow balancing.

As lean systems thinking is implemented, the amount of training that employees receive:

Tends to increase.

Taichi Ohno, the founder of lean/just-in-time, when he came to America in the 1950s was most impressed with which of the following American developments?

The American supermarket

Which of the following are NOT associated with quality at the source?

Total productive maintenance

In which operational setting has lean/just-in-time experienced the lowest levels of acceptance/implementation?

Turbulent business settings

Which of the following is an important belief found in lean cultures?

Waste is a symptom.