TOM 3010 Ch 08, Lean Operations

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

alert

The term kaizen means "process __"

improvement

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

more

What information is provided by calculating target manpower?

number of workers required

How should items be transported in order to implement single unit flow?

piece-by-piece

The P in TPS stands for

protected

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

Match the Japanese term to its meaning.

Muda <--> Waste Mura <--> unevenness in flow Muri <--> overburdening a machine or operator with work

Automation refers to sutomonation with a __ touch

human

The eighth source of waste is the waste of __ intellect.

human

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

increase

Genchi genbutsu emphasizes solving problems by _blank​_.

interviewing stockholders

A rapid flow with little or no __ is one of the pillars of TPS.

inventory

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

pull

Shorter Blank______ allow the operation to switch between models more frequently, thereby helping synchronize the process with demand and making the operation lean.

setups

An operation is lean if it simultaneously strives for a reduction of __ in its capacity and in the time a flow unit spends in the system.

waste

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

waste

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

Which are advantages of U-shaped organization of processing flow?

-Allows employees to assist each other -Increases employee flexibility -Encourages multitasking

What are two terms for merging human intelligence with the power of machines?

-Autonomation -Jidoka

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

-Container size -Demand rate -Replenishment time

Which factors suggest that kanban is the best inventory control system to use?

-Cost and effort to store products are low -Products required with short lead time

Which factors indicate that a make-to-order system should be used?

-Customers are willing to wait for their orders -Products are hard to store -Products are expensive

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

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

What information is required to compute takt time?

-Demand rate -Available time

What are examples of waste of a resource's time?

-Duplication of worker efforts -Idle time on machines

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?

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

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

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.

What are the best perspectives for making time visible?

-the flow unit -inventory

1)Non-value-added work 2) value-added work

1) necessary because of how current process operates 2) necessary to transform flow unit from inputs to output the customer wants

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

Causes them to slow down

Who is considered the father of scientific management?

Frederick Taylor

What is the major advantage of the kanban system?

It limits inventory to just what is needed.

the Japanese word __ describes the action of detecting quality problems, stopping the process, and alerting the operator.

Jidoka

Which of the following is a pillar in the house representation of TPS?

Just-in-time production

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

Kanban

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

Poka, yoke

The Japanese word __-__ describes the process of preventing the recurrence of a problem by implementing improvements.

Poka, yoke

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

Safety

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

Information turnaround time depends on the size of the__ , between the upstream and downstream resource.

buffer

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

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

What is the best definition of kaizen?

continuous improvement

High inventory levels tend to _blank​_ quality problems.

cover up

In TPS, quality problems are exposed and fixed through a process called __-stop-alert

detect

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

detect

By creating "baton-passing" zones a process can absorb __ in worker speeds and starting times.

differences

OEE stands for overall equipment

effectiveness

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

A benefit of the U-shaped line is that it allows for more worker _blank​_.

flexibility

In the Toyota Production System, insights of which employees are leveraged to improve a process?

front-line

The longer the replenishment time, 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

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

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

inventory

Which term refers to shutting down a machine upon detection of a problem?

jidoka

In a __ system, production instructions are communicated to an upstream step when there is consumption at a downstream step

kanban

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

labor

production __ is used to smooth out variability in demand.

leveling

__ inventory helps detect-stop-alert as it makes quality problems more immediately apparent.

low

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

lowering costs

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

make-to-order

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

muda

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

order

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

overproduction

Which principle of operational excellence refers to respectful interactions with employees that emphasize skill development and growth?

people and partners

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

poor

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

processes

One unit flow makes staffing simpler as you only need to compare __ time to takt time.

processing

What aspect of the Toyota Production System inspired James Womack to coin the term "lean"?

production success

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

Which type of system allows inventory to keep accumulating?

push

Which factor should govern the speed of a process?

rate of demand

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

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

steady, even if it is slow

In TPS, quality problems are exposed and fixed through a process called detect-__-alert

stop

To implement single unit flow, you should operate at __ time.

takt

How does one unit flow affect feedback?

Defective units are found sooner

The more available time, the __ the takt time.

more

In the house representation of TPS, how many pillars support the roof?

two

Mura refers to a(n) __ workflow.

uneven