Ch 8 SB

Upon discovering a defect, which of the following actions would represent the TPS philosophy of quality? (Check all that apply.)

-Thoroughly analyze the root cause of the problem. -Pull a cord that stops the production line immediately.

If an individual works 8 hours a day and after a process improvement his time spent on value added activities increases then his OEE will _blank​_.

increase

Which are factors in figuring how many containers to use in a kanban system?

-Container size -Demand rate -Replenishment time

What information is required to compute takt time?

-Demand rate -Available time

Which are elements of make-to-order systems?

-High storage costs -Customers willing to wait -Low volume, high variety

Which are elements of kanban systems?

-High volume, low variety -Low storage costs -Short lead time

What actions were organizations following Taylor's principles of scientific management most likely to take?

-Hire industrial engineers -Study worker movements -Demand high productivity

Which two terms are used to describe smoothing the flow of a process?

-Production leveling -Heijunka

Which are factors in figuring replenishment time?

-Setup time -Time to produce a container of units -Transportation time

What factors are needed to compute target manpower?

-Takt time -Labor content

What are the best perspectives for making time visible?

-The flow unit -Inventory

If parts flow from machine A to machine B and then to machine C, then which pair of machines can be farther apart from each other?

A and C

Which production schedule for products of type A and B is a result of production leveling?

ABABABABABABABAB

Why is the added value of a flow unit not exactly the same as its labor content?

All processing times do not add value.

What was the basic flaw in Taylor's view of workers?

As animals who had to be trained

What effect have large buffers of inventory been shown to have on workers?

Causes them to slow down

What is the best definition of kaizen?

Continuous improvement

Who is considered the father of scientific management?

Frederick Taylor

Which kind of time is an example of muda?

Idle

What is the major advantage of the kanban system?

It limits inventory to just what is needed.

_blank​_ is the process control system wherein an upstream resource replenishes what demand has withdrawn from the downstream.

Kanban

Which action is most likely to lead to improvement in a demand-constrained process?

Lowering costs

Suppose demand for a product is 100 units a day and a factory produces seven days a week. Which production schedule would be in line with the TPS philosophy toward pace?

Make 100 units every day

According to Little's Law, how does less inventory affect response times?

Makes them shorter

What information is provided by calculating target manpower?

Number of workers required

What type of waste is involved when a process creates too many flow items too soon?

Overproduction

Which principle of operational excellence refers to a long-term approach that favors quality and capabilities over short-term financial goals ?

Philosophy

Which principle of operational excellence refers to continuous process flows that match supply with demand?

Processes

In a kanban system, what triggers a production order?

The return of an empty container

Under the principles of genchi genbutsu and kaizen, who should collect data how work is performed in order to improve the process?

Those performing the work

In TPS, quality problems are exposed and fixed through a process called detect-stop-___

alert

___ is a system that consists of a visible board and a cord running adjacent to an assembly line that lets an employee stop a line when a problem is detected.

andon

To understand how much improvement potential there is one must first measure what percentage of a machine's or a worker's ___ is used productively.

capacity

Genchi genbutsu emphasizes solving problems by _blank​_.

collection and analysis of data by front-line workers

High inventory levels tend to _blank​_ quality problems.

cover up

Information turnaround time refers to the time between creating a ___ at an upstream resource and detecting it at a downstream resource.

defect

Inventory is controlled in a Kanban system because production occurs at an upstream resource only when it has an ___ container.

empty

The TPS motto related to reducing rework is "Do it right the ___ time."

first

The higher the demand rate, the _blank​_ the number of Kanban cards.

greater

The higher the safety stock, the _blank​_ the number of Kanban cards.

greater

The basic philosophy of TPS is that the production process should _blank​_ production when a quality problem is discovered.

halt

The more available time, the ___ the takt time.

higher

Autonomation refers to automation with a ___ touch.

human

The term kaizen means "process ___ ."

improvement

If a process improvement effort decreases the amount of time spent on non-value-added activities, then the value-added percentage will _blank​_.

increase

Little's Law enables one to calculate flow time, while flow rate is constant, indirectly by examining ___.

inventory

In a ___ system, production instructions are communicated to an upstream step when there is consumption at a downstream step. (Enter only one word per blank.)

kanban

Which term refers to an inventory control system where parts delivery instructions are triggered by the consumption of parts at the downstream step?

kanban

When analyzing why flow unit time is wasted, one compares ___ content with flow time.

labor

In a _blank​_ system, each flow unit is explicitly tied to a specific customer order.

make-to-order

The longer the information turnaround time the _blank​_ time an upstream resource will spend producing defective units.

more

Mura leads to muri, which drives up ___ , or, waste.

muda

Resources that are ___ to each other in the process flow diagram should also be co-located in physical space.

next

Make-to- ___ is the process control system wherein work is released into the system only after a customer order has occurred.

order

Make-to-___ is the process control system wherein work is released into the system only after a customer order has occurred.

order

The Japanese term for fool-proofing an activity is ___ ___

poka yoke

High inventory and _blank​_ quality go hand in hand.

poor

In a ___ system, inventory is a variable of managerial decision-making.

pull

In a _blank​_ system, inventory is a managerial decision.

pull

In which type of system does production occurs only because there is demand?

pull

In a ___ system, flow units are allowed to enter the process independent of the current amount of inventory in process and the demand rate.

push

Two forms of waste are waste of a flow unit's time and waste of a ___ time.

resource

Idle time is a waste of a ___ time.

resource's

The objective of the OEE framework is to identify what percentage of a _blank​_ time is value-added and what percentage is wasted.

resource's

___ stock is extra inventory kept in the system in case of defects or breakdowns.

safety

What is the TPS philosophy consider the best pace of a production process?

steady, even if it is slow

Mura refers to a(n) ___ workflow.

uneven

The needless waste of time and worker movements was defined by Ohno as ___.

waste

The time a flow unit spends in inventory is _blank​_ time.

wasted

The time a flow unit spends in transportation is _blank​_ time.

wasted

Ideas for fool-proofing an activity in order to prevent a previously detected defect from recurring often involve a new ___ standard.

work