OM323 Chapter 8
Match the linked steps of level, mixed-model scheduling (in the left column) with their respective description (in the right column). A) Load leveling B) Mixed-model scheduling a) Calculating the average rate of production needed for each item based on the overall TAKT time. b) Deciding the method to distribute the production of different products over the workday.
A) a) B) b)
Match the different focused factories (in the left column) with their respective description (in the right column). A) Market-focused B) Product-focused a) Supplying a range of products to customers with similar or complementary demand patterns and value propositions b) Production of products that have similar technological processing requirements
A) a) B) b)
Match the steps used for reducing long setups (in the left column) with their respective procedures (in the right column). A) Separate internal and external setups B) Convert internal setups to external setups C) Streamline all activities in a setup a) Segregate setup procedures that occur while an equipment sits idle from the setup activities that workers complete while the equipment operates. b) Examine the flow process chart and develop a new process. c) Eliminate the activities performed t
A) a) B) b) C) c)
Match the types of wastes (given in the left column) with their respective root causes (given in the right column). A) Processing B) inventory C) Motion D) Product defects a) Product changes without process changes, just-in-case logic, lack of communication, redundant approvals and inspections, undefined customer requirements, and stop-gap measures that become routine b) Just-in-case logic, incapable processes (poor quality), unbalanced workload, unreliable supplier shipments, and inadequate
A) a) B) b) C) c) D) d)
Match the activities of a 5-S program in English (in the left column) with their corresponding Japanese words (in the right column). A) Sort B) Straighten C) Scrub D) Systematize E) Standardize a) Seiri b) Seiton c) Seiso d) Seiketsu e) Shitsuke
A) a) B) b) C) c) D) d) E) e)
Match the different types of wastes (in the left column) with their respective definitions (in the right column). A) waste of overproduction B) waste of waiting C) processing waste D) waste from product defects E) waste of motion a) Processing more units than necessary b) Resources wasted waiting for work c) Excessive or unnecessary operations d) Waste due to unnecessary scrap, rework, or correction e) Unnecessary or excessive resource activity
A) a) B) b) C) c) D) d) E) e)
Match the important principles of lean systems (in the left column) with their respective descriptions (in the right column). A) Precisely specify value for each specific product B) identify the value stream for each product C) Make value flow without interruptions D) Let the customer pull value from the producer E) Pursue perfection a) The final consumer ultimately determines the value of a product or service b) A firm must clearly understand and link together all of the activities involved
A) a) B) b) C) c) D) d) E) e)
Match the types of events causing problems for lean supply chains (in the left column) with their respective examples (in the right column). A) operational/technological B) social C) natural/hazard D) economy/competition E) Legal/political a) Forecast errors, capacity constraints, and IT disruptions b) Labor strikes and sabotage c) Fire, flood, monsoon, and earthquake d) Interest rate fluctuations and bankruptcy of supply partners e) Lawsuits, wars, border customs, and regulations
A) a) B) b) C) c) D) d) E) e)
Match the types of wastes (given in the left column) with their respective symptoms (given in the right column). A) Waiting B) Transportation C) Processing D) Inventory E) Motion F) Product defects a) underutilizations of resources, reduced productivity, increase in investment and idle equipment b) Reduced productivity, large reach, excess handling, and reduced quality c) Rework, repairs, and scrap, customer returns, loss of customer confidence, and hazardous waste generation d) Extra handlin
A) a) B) d) C) f) D) e) E) b) F) c)
Match the activities of a 5-S program (in the left column) with their respective intent (in the right column). A) Sort B) Straighten C) Scrub D) Systematize E) Standardize a) Put everything in an orderly fashion so that it can be located. b) Red tag suspected unnecessary items. After a monitoring period, throw out unnecessary items. c) Make cleaning and checking routine. Set the standard, train and maintain. d) Clean everything and eliminate the sources of dirt. e) Continuously improve process
A) b) B) a) C) d) D) c) E) e)
Match the types of waste in product design (in the left column) with their respective causes (in the right column). A) Complexity B) Variability C) Sensitivity D) Danger E) High skill a) Product design results in a situation where the resulting product can be easily flawed or damaged during factory operations. b) Many different processes c) Product specifications make it difficult to control processes on the factory floor. d) The use of a product design may unintentionally expose users or the
A) b) B) c) C) a) D) d) E) e)
Identify the true statements about the application of lean systems within a firm. (Check all that apply.) a) The design of training programs needs to be driven by lean objectives. b) The lean approach requires tight coordination of marketing, sales, and operations to increase communication and decrease order processing lead times. c) Self-motivated employees who have a strong interest in solving problems through process innovation must be hired. d) Employees must emphasize process innovation ra
a) The design of training programs needs to be driven by lean objectives. b) The lean approach requires tight coordination of marketing, sales, and operations to increase communication and decrease order processing lead times. c) Self-motivated employees who have a strong interest in solving problems through process innovation must be hired.
Identify the true statements about Kaizen Events. (Check all that apply.) a) They are completed in less than a week. b) They require managers to rely on the reports of the problems and issues. c) They rely on visual signals to identify the exact locations of problems in the system. d) In this process, cross-functional team members document a process, assess the performance, and develop and document the implemented process changes.
a) They are completed in less than a week. d) In this process, cross-functional team members document a process, assess the performance, and develop and document the implemented process changes.
Identify the true statements about total productive maintenance (TPM). (Check all that apply.) a) Typical TPM programs emphasize shop floor organization. b) A TPM program requires disciplined adherence to operating procedures and rigorous equipment design and upkeep. c) TPM focuses on fixing problems. d) In addition to manufacturing equipment, TPM can be applied to computer networks and automated service kiosks.
a) Typical TPM programs emphasize shop floor organization. b) A TPM program requires disciplined adherence to operating procedures and rigorous equipment design and upkeep. d) In addition to manufacturing equipment, TPM can be applied to computer networks and automated service kiosks.
Identify the prescriptions that the application of lean principles to supply chain relationships leads to. (Check all that apply.) a) Work with suppliers and not against them. b) Keep the protection from buffers at a bare minimum c) Buy to achieve the lowest total cost. d) Keep distances between partners short. e) Eliminate the need for inventory, lead time, and capacity buffers. f) Treat problems as a symptom and focus on the factors that contributed to the emergence of that problem. g) M
a) Work with suppliers and not against them. c) Buy to achieve the lowest total cost. d) Keep distances between partners short. f) Treat problems as a symptom and focus on the factors that contributed to the emergence of that problem. g) Minimize the number of suppliers.
In _____, activities in the operating processes are initiated by actual customer demands, not by schedules that are based on forecasts. a) a pull system b) employee empowerment c) total productive maintenance d) a lean system culture
a) a pull system
Many researchers have argued that the reliance on lean resulted in all but which of the following during the COVID-19 pandemic? a) greater slack capacity b) fewer supply options c) lower buffers
a) greater slack capacity
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. a) standardization b) gemba kaizen c) simplification d) poka-yoke
a) standardization
_____ organizes operations systems by grouping together similar customers and then designing and implementing product systems to serve these specific customers. a) TAKT time flow balancing b) A focused factory c) A pull system d) A lean system culture
b) A 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. a) Lean system culture b) Group technology c) Pull system d) Total productive maintenance
b) Group technology
Identify the lean systems tools that are used for development of facilities and resources. (Check all that apply.) a) Kaizen Events b) Group technology c) 5-S program d) Total productive maintenance e) Focused factories
b) Group technology d) Total productive maintenance e) Focused factories
Identify the different terms used to describe lean systems. (Check all that apply.) a) Total quality management b) Just-in-time manufacturing c) Toyota Production System d) Zero inventories e) Continuous review model f) Lean production g) Stockless production
b) Just-in-time manufacturing c) Toyota Production System d) Zero inventories f) Lean Production g) Stockless production
______ is a short-term approach to enhancing efficiency that focuses on improving an existing process or an activity within a process. a) Jidoka b) Kaizen Event c) Quality at the source d) Stop-and-fix system
b) Kaizen Event
Identify the benefits of lean systems. (Check all that apply.) a) A firm can increase the minimum amount of output the firm needs to sell in order to make profit. b) Lean systems lower the variable production costs associated with labor, materials, and energy. c) A firm can significantly lower its break-even production quantity. d) Lean systems raise the unit profitability of products.
b) Lean systems lower the variable production costs associated with labor, materials, and energy. c) A firm can significantly lower its break-even production quantity. d) Lean systems raise the unit profitability of products.
Identify the lean systems tools that are used for continuous process improvement. (select all that apply) a) Total productive maintenance b) Poka-yoke (fail-safing/mistake-proofing) c) Process analysis/Value stream mapping d) 5-S program e) Visual control f) Kanban (pull) scheduling g) TAKT time flow balancing h) Simplification/Standardization i) Kaizen Events j) Quality at the source
b) Poka-yoke (fail-safing/mistake-proofing) d) 5-S program h) Simplification/Standardization i) Kaizen Events j) Quality at the source
______ is the practice of eliminating defects at their root cause origination points. a) Jidoka b) Quality at the source c) Kaizen Event d) Stop-and-fix system
b) Quality at the source
_______ 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. a) TAKT time flow balancing b) Statistical process control c) Push scheduling d) Level, mixed model scheduling
b) 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. a) Poka-yoke b) Stop-and-fix system c) Jidoka d) Kaizen Event
b) Stop-and-fix system
Identify a scheduling approach aimed at synchronizing the output rate with the rate of customer demand. a) Focused factory b) TAKT time flow balancing c) Lean system culture d) Pull system
b) TAKT time flow balancing
_______ works to identify and prevent all possible equipment breakdowns. a) A pull system b) Total productive maintenance c) A lean system culture d) Employee empowerment
b) Total productive maintenance
A manager making use of the Kanban scheduling authorizes production or withdrawal based on the Blank______. a) work flow b) actual customer demand c) order point d) work capacity
b) actual customer demand
In lean systems, _____ focuses on eliminating non-value-added activities in a process. a) poka-yoke b) simplification c) jidoka d) gemba kaizen
b) simplification
_____ focuses on developing technological features of equipment and processes that automatically detect and flag problems. a) Kaizen Event b) Stop-and-fix system c) Jidoka d) Quality at the source
c) Jidoka
In ______, activities are initiated and products are moved according to a schedule, irrespective of whether or not a customer demands it. a) a pull system b) a focused factory c) a push scheduling d) TAKT time flow balancing
c) a push scheduling
What is a graphic mapping technique that helps managers understand the material and information flows of a product as it goes through a process? a) trend analysis/decision tree mapping b) scenario analysis/definitive mapping c) process analysis/value stream mapping
c) process analysis/value stream mapping
______ is a scheduling system that builds output in response to actual customer demand. a) Heijunka scheduling b) Push scheduling c) Mixed-model scheduling d) Kanban scheduling
d) Kanban scheduling
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? a) Focused factories b) Group technology c) Total productive maintenance d) TAKT time flow balancing
d) TAKT time flow balancing
Level, mixed-model scheduling is also known as ______.
heijunka
_____ ______ is the application of lean principles and tools to the task of designing products.
lean design
The _____ _____ approach is a philosophy that emphasizes the minimization of the amount of all resources used in the various activities of an enterprise.
lean systems
______ _____ is the process used to reduce setup and changeover times with the goal of making the output of smaller batches more efficient.
setup reduction
______ ______ makes current performance and potential problems immediately visually apparent.
visual control
True or False: The COVID-19 pandemic showed that TQM is the best management system during times of crisis.
False
True or false: Every operational setting and business sector implements the same level of lean systems in application and practice.
False
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
Value stream mapping considers which of the following factors? a) Capacity, quality, and variability. b) Maintenance, run-time, and critical stock. c) Labor costs, direct material costs, and overhead costs.
a) Capacity, quality, and variability.
Identify the major goals of lean design. (Check all that apply.) a) Design products that support corporate strategic objectives. b) Design products based on their similarities in design features. c) Design products that exactly meet customers' needs. d) Design products that reduce/minimize the opportunities for waste.
a) Design products that support corporate strategic objectives. c) Design products that exactly meet customers' needs. d) Design products that reduce/minimize the opportunities for waste.
Identify the different terms used for poka-yoke. a) Fail-safing b) Value stream mapping c) Mistake proofing d) Future state map
a) Fail-safing c) Mistake proofing
Identify the true statements about group technology. (Select all that apply) a) In group technology, part families are created based on the similarities in design features. b) It groups together the same types of equipment in departments. c) It assigns workers to highly specialized, individual machines and tasks. d) It is also called cellular manufacturing
a) In group technology, part families are created based on the similarities in design features. d) It is also called cellular manufacturing
Identify the benefits of the application of the lean systems approach across the supply chain. (Check all that apply.) a) In stable environments, lean can enhance the performance of the supply chain. b) Suppliers and customers better understand each other's needs and capabilities. c) Low coordination and integration of transportation system between supply chain partners processes become sufficient. d) Application of lean approach leads to improved quality, reduced costs, and improved customer
a) In stable environments, lean can enhance the performance of the supply chain. b) Suppliers and customers better understand each other's needs and capabilities. d) Application of lean approach leads to improved quality, reduced costs, and improved customer service.
Identify the lean systems tools that are used for operational scheduling and control. (Check all that apply.) a) Kanban (pull) scheduling b) Statistical process control c) Setup reduction d) Visual control e) Mixed model scheduling f) TAKT time flow balancing g) Total productive maintenance h) Group technology
a) Kanban (pull) scheduling b) Statistical process control c) Setup reduction d) Visual control e) Mixed model scheduling f) TAKT time flow balancing
_____ is an emphasis on redesigning processes in such a way as to make mistakes either impossible or immediately apparent to the worker. a) Poka-yoke b) A 5-S Program c) Gemba kaizen d) Jidoka
a) Poka-yoke
Identify the reasons why employees are viewed as critical resources for success in the lean systems philosophy. (Check all that apply.) a) Power in their hands b) Working in teams c) Source of flexibility d) Innovations e) Diversity f) Acceptance
a) Power in their hands b) Working in teams c) Source of flexibility f) Acceptance
Identify the methods by which lean systems can lower the break-even production quantity of a firm. (Check all that apply.) a) Reducing fixed overhead costs b) Checking waste costs associated with the fixed costs of facilities c) Increasing variable production costs d) Increasing the contribution margin
a) Reducing fixed overhead costs d) Increasing the contribution margin
Identify the examples of visual controls. (Check all that apply.) a) SPC (statistical process control) charts b) Andon boards c) Written work procedures d) Lighting systems e) RFID
a) SPC (statistical process control) charts b) Andon boards d) Lighting systems
