Operations Management Chapter 14
Select the best definition of JIT II. A - When a JIT system increases speed of production by at least 50% from adoption of practice B - Vendors manage inventory on Buyer's premises C - When an organization uses both Just-in-Time AND Lean principles in their operation.
B
Select the best definition of Value Stream Mapping. A - A map of transportation of inputs from the tier of suppliers to the factor to determine optimal routes and document cost (material and conveyance) B - A visual tool to systematically analyze the flow of materials and information involved in bringing a product or service to a customer C - A schematic diagram of the factory floor showing equipment, workstations, stock room supply lanes to examine production flow.
B
The acronym WIP stands for what? A - Wrap-In-Plastic B - Work-In-Process C - When-In-Production D - Work-In-Plant
B
What are some of the benefits of Lean Operations? A - Longer lead times, higher profits, smaller facilities B - Lower costs, greater productivity, higher quality C - Longer cycle times and higher quality
B
What characteristic of lean systems enables equipment flexibility and output variety without disruption in a lean system? A - Lean culture B - Quick changeovers C - Waste reduction D - Use of teams
B
Which of the following is an example of "mistake proofing" production (also known as poka-yoke in Japanese)? A - Using automation instead of human labor since machines do not make mistakes. B - Designing components that can only be installed one-way (not upside down or backwards). C - Putting an "inspected by X" sticker on each unit so any defects are traceable back to the employee.
B
Which of the following is an example of standardized parts supporting Lean. A - Proctor-Silex toaster assembly instructions indicate to install the electrical cord appropriate for the destination country of origin. B - Same hard drive casing is used in all Dell Computers so assembler learns how to install one part number across all models of computers. C - Each ceramic casserole dish made by Corning requires the same oven temperature for curing.
B
Which of the following is an example of "elimination of disruptions" for Lean services. A - Standardize procedures as much as possible for the services offered B - Cross-train workers but try to avoid duplication of work while servicing customers C - Try to avoid having workers who are servicing employees also answer telephones
C
Which of the following is not a benefit of lean systems? A - Increased flexibility due to quick changeovers B - Reduced waste C - Economies of scale D - Reduced cycle times
C
Under the kaizen philosophy, who should be involved? A - Top management B - Middle managers C - Workers D - Everyone
D
True or false: Any production system can convert to a Pull system, regardless of volume, mix or product design.
False
True or false: When converting to Lean, management must decide, "All or Nothing"--there is no incremental approach.
False
In the kaizen philosophy, ________ is the enemy.
waste
At Toyota Lean Manufacturing is focused on Waste Reduction in every aspect of process. What is meant by "waste" in this context? A - Waste is anything that does not add value to or interferes with production. B - Waste is any environmentally hazardous by-product of manufacturing. C - Waste is all refuse (garbage) collected at each step of operations and must be disposed of responsibly.
A
Direct suppliers must be able to support _____ just-in-time deliveries of _____ of parts. A - frequent, small batches B - frequent, large batches C - infrequent, small batches D - infrequent, large batches
A
In Lean process design what is the ideal lot size in numbers of units? A - 1 B - 1,000 C - 10 D - 100 E - As large as possible
A
In Lean terminology waste refers to what? A - Any aspect of a process which is non-value added B - By-products of production such as hazardous material, scrap, recyclables (paper, cardboard, styrofoam, etc.) C - Safety and buffer stock generated to avoid risk
A
In order to make a JIT/Lean system flexible to handle a variety of products, what two things must be reduced? A - Long setup/changeover times and long lead times from vendors B - The number of employees on the production line and quality defects C - The time to train employees on a new product and excess inventories
A
One principle of lean is eliminating _____ to create _____. A - waste; flow B - production; value C - processes; perfection
A
Select the best definition of Lean Operations. A - A flexible system of operations using fewer resources than a traditional system B - A system of operations on a limited budget with the minimum number of employees C - Operations which do not produce enough to cover overhead costs and must be changed
A
Single minute exchange of die (SMED) is a system developed at Toyota for reducing what? A - Setup time B - Recurring costs C - Number of parts D - Variable costs
A
Value Stream Mapping is a technique that originated at Toyota, where it was referred to as _____. A - Material and Information Flow Mapping B - Value Flow Mapping C - Data Mapping D -Work Method and Mistake Mapping
A
What are the two parts of Autonomation, a Lean quality improvement technique? A - Defect detection and work stoppage B - Continuous improvement and results communication C - Waste reduction and process control D - Process design and mistake proofing
A
What is the most important organizational/cultural aspect without which Lean implementation is doomed? A - A spirit of cooperation and mutual respect among management, employees, vendors B - Regular work day start and stop times with regimented break times C - A strong work ethic and a desire to produce at high quality levels D - A low ratio of unionized labor to non-unionized labor in Buyer and Seller organizations
A
When services adopt Lean operations what is usually the main focus of improvement? A - Time to perform a service B - Upgrade of existing facilities C - Inventory levels in stock room D - Quality of service as perceived by the customer
A
Match the transaction type and the description described as part of Miller and Vollmann's "hidden factory". A - Logistical transactions B - Balancing transactions C - Quality transactions 1 - Include forecasting, production planning, production control, procurement, scheduling, and ordering processing. Associated costs relate to the personnel involved in these and supporting activities. 2 - Include determining and communication specifications, communicating specifications, monitoring, recording, and follow-up activities. Costs relate to appraisal, prevention, internal failures and external failures. 3 - Include ordering, execution, and confirmation of materials transported from one location to another. Related costs cover shipping and receiving personnel, expediting orders, data entry, and data processing.
A - 3 B - 1 C - 2
Match each of the 5S's of the Lean visual work place management system to its definition. A - Sort B - Straighten C - Sweep D - Standardize E - Self-discipline 1 - Organize the work place so that the needed items can be accessed quickly and easily 2 - Keep the workplace clean and ready for work. Perform equipment maintenance regularly 3 - Decide which items are needed to accomplish the work, and keep only those items. 4 - Use standard instructions and procedures for all work 5 - Make sure that employees understand the need for an uncluttered work place
A - 3 B - 1 C - 2 D - 4 E - 5
Lean, which originated at Toyota, uses many Japanese terms for its concepts. Match the term with the definition. A - Muda B - Kanban C - Heijunka D - Kaizen E - Jidoka 1 - Continuous improvement in the system 2 - Leveling volume and variety of work to reduce variation in the process 3 - Waste an inefficiency 4 - A manual system to control the movement of parts and materials using containers and signals 5 - 'Quality at the source" - work is stopped immediately when a defect occurs
A - 3 B - 4 C - 2 D - 1 E - 5
Match the four aspects of Product Design which support the goals of Lean/JIT systems with their definition. A - Standard Parts B - Modular design C - Cable production quality D - Concurrent Engineering 1 - Production systems were product and process design have reduced/eliminated defects 2 - Team approach involving each grout in product design from the beginning instead of serially from development to delivery 3 - Standardized sub-assemblies (clusters of parts) to simplify bills of material, training, and assembly of final product 4 - Having fewer parts across product lines which reduce procurement, inspection costs
A - 4 B - 3 C - 1 D - 2
Match these categories with their 5W2H term. A - Subject B - Purpose C - Location D - Sequence E - People F - Method G - Cost 1 - Why 2 - Where 3 - Who 4 - When 5 - How 6 - How much 7 - What
A - 7 B - 1 C - 2 D - 4 E - 3 F - 5 G - 6
Select all that apply In a Lean organization workers are treated as assets. What does this mean in a lean organization? A - Workers are well-trained in Lean philosophy and methods. B - Workers are each given a dollar value for cost accounting purposes. C - Workers are given authority to make decisions that effect their work.
A and C
Select all that apply What are some of the benefits of cross-training workers, a personnel management method often used in a Lean organization? A - Helps with system bottlenecks for line balancing purposes B - Makes workers get along better C - Increases bonus incentive opportunities D - Adds flexibility when a co-worker is absent
A and D
Select all that apply In what ways does JIT (Just-In-Time) impact the supply chain? A - Loading docks busier from more frequent orders B - Suppliers are under pressure to deliver on-time C - Vendors may charge more per unit for smaller shipments D - Vendors have to bid for orders and suppliers often choose lowest price
A, B, and C
Select all that apply What are some of the major obstacles encountered when converting to Lean/Just-in-time operations from traditional methods? A - Management may resist because Lean shifts some of their responsibilities to workers. B - The organization's culture may not be compatible with the Lean philosophy. C - Suppliers may resist for various reasons--frequent deliveries, burden of quality, etc. D - Workers may be uneasy about learning statistics for Six Sigma process control.
A, B, and C
Select all that apply Which of the following attributes are characteristics of lean systems? A - Continuous improvement B - Quick changeovers C - Waste reduction D - Maximum inventory
A, B, and C
Select all that apply How do small lot sizes support Lean process design? A - Work-in-process inventory is reduced B - More flexibility to meet customer demand C - They do not support it--larger lots are more efficient D - Inspection and rework costs are less
A, B, and D
Select all that apply The success of a lean system relies heavily on which of the three items that follow? A - Effective teamwork B - Achieving a lean thinking culture C - Involvement of the community D - Leadership commitment
A, B, and D
Select all that apply Inventories are buffers that tend to cover up recurring problems such as which of the following? A - Equipment breakdowns B - Engineering changes C - Bottlenecks D - Training issues E - Quality defects
A, C, D, and E
Select all that apply What are the main considerations to be made prior to adoption of Lean operations? A - Cost and other resources required to convert to Lean B - How many employees can learn to speak Japanese C - Whether running on a tight schedule is desired D - Length of time to convert from traditional systems
A, C, and D
Select all that apply Select the four building blocks which support the goals of Lean/Just-in-Time systems from the following list: A - Personnel & organization elements B - Marketing, finance and operations C - Training, culture and facilities D - Manufacturing, planning and control E - Product design F - Process design
A, D, E and F
A Six Sigma process is under what kind of control? A - 100% inspection of product B - Statistical process control C - Governmental regulatory control D - ISO 9000 scrutiny
B
All of the following are advantages of level loading except which? A - Provides certainty to the system B - Ensures uniform customer demand C - Makes production scheduling easier D - Requires uniform amounts of inputs from suppliers making ordering simple
B
All of the following are benefits of a limited work-in-process system EXCEPT _______. A - saves on rework and scrap if design changes B - greater cycle time variability; WIP = cycle time x arrival rate C - increased production flexibility from lean production D - lower carrying costs for reduced inventory
B
All of the following are benefits of the 5S Lean "housekeeping" system except which? A - Better employee morale B - Increased risk of accidents C- Increased productivity D - Improved appearance for visitors
B
How does setup time reduction contribute to Lean process design? A - More setups cost the company money so the fewer required the better. B - Smaller lot sizes mean more setups (changeovers of equipment). Smooth, rapid flow is the goal. C - Productivity is increased with larger lot sizes and fewer setups between lots.
B
What are the two common threads across all the building blocks of Lean/JIT systems. A - Waste and Inefficiency B - Speed and Simplicity C - Customer focus and quality D - Kaizen and learning
B
What is the ultimate goal of a Lean system? A - Eliminate excess process steps to increase customer satisfaction B - Achieve a smooth, uninterrupted flow where supply equals demand C - Minimize inventories and deliver to customers on time
B
When converting to Lean/Just-in-time operations what are workers usually most concerned about? A - The efficiency of top management labor B - Loss of their job as production efficiency increases C- Shorter setup times for each production batch
B
Which of the following accurately explains the difference between kanban and CONWIP (constant work-in-process) as methods for controlling WIP? A - Kanban moves work downstream as it is completed. CONWIP each workstation controls their own WIP. B - Kanban signals work to move when the next work station is ready. In CONWIP a unit enters the system only when a unit exits. C - Kanban cards flag when a bin is empty. CONWIP uses andon lights (green, yellow, red) to signal supply status.
B
Which of the following statements is correct about planning a successful conversion to Lean/Just-in-time operations. A - Conversion should be accomplished quickly, not gradually, to realize the maximum benefit. B - Management and employees must be convinced of benefit and receive training prior to conversion to avoid obstacles. C - When converting a production line, begin at the start and progress to the end of the line. D - Vendors should be converted to JIT delivering first, before implementing in the Buyer's organization.
B
Which of the following statements is true about Lean Manufacturing? A - Lean Manufacturing started in California at GM. B - Lean Manufacturing started in Japan at Toyota. C - Lean Manufacturing began in America and was exported to Japan. D - Lean Manufacturing was coined by Shewhart at Bell Labs.
B
Select all that apply Identify the true statements about Kanban. A - It is an automated inventory control system which stores and locates parts with minimal human labor. B - It requires workers to signal when they have run out of parts at their assembly operation. C - It replaces material or parts only when needed, so as to avoid overproduction.
B and C
Select all that apply Which of the following statements about Just-In-Time (JIT) systems is/are correct? A - JIT systems require minimal coordination and effort. B - JIT is often used to describe Lean systems. C - Conversion to JIT systems entail some risk. D - JIT systems are demand driven.
B, C and D
Select all that apply JIT/Lean, a low-inventory scheduling system with minimal waste where supply equals demand, must have what in place to work properly? A - Managers with bonus incentives for on-time delivery B - Flexibility to handle a variety of products/services C - No disruptions from quality problems D - Processes and equipment with high reliability to minimize breakdowns E - Profits sufficient enough to re-capitalize equipment F - Employees who continuously improve the process
B, C, D, and F
How is Lean different from Six Sigma? A - Lean is used primarily in manufacturing sector and Six Sigma is used in the Service industries. B - There is no difference. They are basically the same techniques. C - Lean focuses on eliminating waste, improving flow while Six Sigma reduces variability.
C
In Lean/JIT systems the burden of ensuring quality of production inputs from vendors shifts from the _____________ to the _______________. A - analyst/supervisor B - seller/buyer C - buyer/seller D - inspector/procurer
C
In a one-shift operation, if the operating time is 480 minutes and there is one 30-minute lunch break and two 15-minute rest breaks, what is the takt time if the demand rate is 70 units per day. A - 10 minutes per cycle B - 5 minutes per cycle C - 6 minutes per cycle D - 7 minutes per cycle D - 8 minutes per cycle
C
In lean systems, production is based on which of the following inputs? A - Strategic plan B - Production schedule C - Customer demand D - Demand forecast
C
JIT II is also known by what other acronym? A - CONWIP (Constant Work-In-Process) B - ERP (Enterprise Resource Planning) C - VMI (Vendor Managed Inventory) D - 5S (Sort, Straighten, Sweep, Standardize, Self-Discipline)
C
Lean systems are designed to ______ inventory storage. A - stabilize B - maximize C - minimize
C
Select the best definition of Just-In-Time (JIT) systems. A - Operations geared toward always delivering to customers on time at the exclusion of other factors such as cost or quality B - A system of operations highly automated with precise timing requiring less labor than traditional systems C - Operational system with highly coordinated activities to deliver goods just as they are needed
C
Select the best definition of level loading. A - Producing enough to keep constant buffer stock for unanticipated customer demand (e.g., always keep 10% of demand for A, B and C in stock room) B - Manufacturing equal amounts of each product (e.g., 50 units each of A, B, & C on Monday and 45 of each on Tuesday, etc. but always uniform ratios) C - Producing at the same rate or quantity each day (e.g., 100 units of A, B, C each day with constant ratios)
C
The 5W2H approach to process improvement is a simple and effective method. What does 5W2H stand for? A - Five weapons, two heuristics B - What if, WIP, Waiting, Waste, Waiver, Hire, Health C - What, Why, Where, When, Who, How, How Much?
C
There are two general approaches to controlling WIP; one is kanban and the other is constant work-in-process (CONWIP). Kanban's control of WIP focuses on _____, while CONWIP'S focus is on _____. A - individual workstations, individual workers B - individual workers, the system as a whole C - individual workstation, the system as a whole D - the system as a whole, individual workers
C
Under the kaizen philosophy, how should improvements be done? A - Things should be kept the same B - Big improvements that take significant time C - Gradually and continuously
C
What is the most serious obstacle to Lean conversion? A - Disgruntled suppliers who refuse to convert B - Employees who do not pay attention in training class C - Management commitment of resources required for conversion D - Improper administration of statistical process control techniques
C
Which of the below statements best describes the difference between a push and pull system of production? A - Push and pull systems differ only by the kanban devices indicating movement to the next operation. B - Push: customer demand drives the pace of work. Pull system work is produced & sent to stock with extra buffer. C - Push: work is sent to the next operation upon completion. Pull: the subsequent operation takes from the preceding.
C
Select all that apply In order to achieve a balanced, rapid flow through a Lean system, disruptions must be minimized. What are some causes of disruptions in production? A - Employee break times B - Training programs to learn new skills C - Equipment breakdowns D - Weekly staff meetings E - Quality problems F - Late deliveries from suppliers
C, E, and F
Autonomation, a quality improvement technique, is known by what Japanese word? A Muda B - Kaizen C - Poka yoke D - Jidoka
D
Failsafing refers to building safeguards into a process to reduce or eliminate the potential for errors during a process. What is the term for this? A - Baka-yoke B - Kaizen C - Kanban D - Poka-yoke
D
How long does it take an organization to convert from a traditional system of operation to Lean/Just-in-Time operation? A - 6 to 10 years B - 6 months to a year C - 2 to 5 years D - 1 to 3 years
D
Select the best definition of takt time, which is used in Lean process design to balance workload. A - The time alloted for workers to take rest breaks during their shift B - The minimum setup time required to support the small lot sizes C - The cycle time needed to remove all bottlenecks D - The cycle time needed to meet the demand rate
D
The benefits of Lean are most easily realized in which Process type? A - Continuous processing B - Job shop C - Batch processing D - Repetitive assembly
D
Which type of transactions in an organization include defining and communicating specifications? A - Balancing transactions B - Change transactions C - Logistical transactions D- Quality transactions
D
Supply chain _________ can inhibit operations due to minimal inventory levels in lean systems.
Disruptions
True or false: In Lean/JIT vendor-buyer relationships, price becomes secondary to other factors such as flexibility, high quality, frequent small deliveries and quick response to problems.
True