Module 5 Inventory

Which of the following will result in a one-piece flow?

. Reducing the transfer batch size to one.

Workstations that are evaluated in terms of efficiencies and % utilization are incentivized to follow a just-in-time system.

False

_____cards are used to signal a preceding workstation that a subsequent workstation is available to process a unit.

Kanban

A_____batch size is the number of units processed before a setup is incurred.

Process

A just-in-time system is sometimes referred to as a ____system

Pull System

Which of the follow is one of principles of "Lean"? a. High Efficiencies b. Pull c. Zero Defects d. Elimination of idle time e. Push f. One Piece Flow g. Takt

Pull, Zero Defects, One Piece Flow, Takt

The buffer frequently takes the form of a______with a fixed number of time slots.

Schedule

The number of units of work-in-process inventory in the buffer should be big enough to protect the bottleneck from being starved.

True

The optimal process batch size will likely vary throughout a process because setup and processing times vary among workstations.

True

The optimal transfer batch size will likely vary throughout a process.

True

Time lost on the bottleneck is time lost for the entire system.

True

Utilizing a resource is using the resource in a way that moves an organization closer to its goal.

True

With a just-in-case system, workstations pass units on to the next workstation just in case the next workstation is able to process the units.

True

With a just-in-time system, a workstation can not pass to a subsequent workstation until the subsequent workstation is available to process the unit.

True

You want to set transfer batch sizes on nonbottleneck resources as small as possible as long as doing so does not turn a nonbottleneck into a bottleneck.

True

When there is time lost in transfer, increasing a workstation's transfer batch size will result in an______ in the efficiency of the workstation.

An increase

The___batch size is the number of units processed before units are passed to a subsequent workstation.

Transfer

A just-in-time system is when a workstation does not pass a unit to a subsequent workstation until that workstation is ready to process the unit.

True

Activating a resource results in the resource processing whenever it has a unit available to process.

True

Which of the following is a pull system?

a. Just-in-Time System

When the just-in-time system inventory control system replaced just-in-case processing, quality improved because

a. Quality issues were identified sooner. b. Quality issues were more likely to be addressed by the resources. c. There was less potential rework.

Reducing transfer batch sizes at all nonbottleneck resources will result in

a. a decrease in work-in-process inventory b. an decrease in manufacturing lead times c. better quality

Which of the following are likely outcomes of cutting (reducing) transfer batch sizes?

a. less work-in-process inventory b. faster manufacturing lead times c. faster makespans d. better quality

A buildup of work-in-process inventory is likely to result in which of the following.

a. longer manufacturing lead times b. poor quality c. stressed workers

Which of the following should managers monitor to detect when the flow into a system is greater than the flow out?

a. manufacturing lead times b. quality c. workers' stress levels

When all workstations worked "in-takt" in the cup stack exercise, quality improved compared to when the workstations processed just-in-case because of which of the following?

a. the bottleneck resource was less stressed b. non-bottleneck resources were less likely to pass a defect to a subsequent workstation c. there was less potential rework

Which of the following is NOT a true statement? Select one: a. With a just-in-case system, the flow into the system is greater than the flow out. b. A just-in-case system is a high inventory system. c. With a just-in-case system, the largest pile of inventory will always be located in-front-of the workstation which dictates the output rate. d. With a just-in-case system, work-in process inventory will continue to increase in the system overtime. e. With a just-in-case system, inventory will accumulate in-front-of the slowest workstation.

c. With a just-in-case system, the largest pile of inventory will always be located in-front-of the workstation which dictates the output rate.

Which of the following statements is false? Select one: a. Activation and utilization of a resource are not necessarily the same thing. b. The level of utilization of a nonbottleneck resource is not determined by its own capacity but by some other constraint in the system. c. When a bottleneck resource feeds a nonbottleneck resource, the level of utilization and activation are the same. d. When a nonbottleneck resource feeds a bottleneck resource, the level of utilization and activation are the same. e. Utilizing a resource means making use of it in a way that moves an organization closer to its goal.

d. When a nonbottleneck resource feeds a bottleneck resource, the level of utilization and activation are the same.

Switching from a JIC system to a JIT system will result in a ____ in manufacturing lead times, a ____in work-in-process inventory and a_____ in rework.

decrease decrease decrease

The key to controlling the buildup of work-in-process inventory is to make the flow into the system_____to the flow out

equal

Drum-Buffer-Rope System

the bottleneck → drum, workstations only pass to subsequent workstation when the subsequent workstations are available → just-in-time system, mechanism which signals the release of a new unit into the system → rope, units of work-in-process inventory located in-front-of the system constraint → buffer, a workstation passes units as soon as it completes processing → drum-buffer-rope