CH 12

True or false: A kanban system produces zero inventory.

False

True or false: For a firm to be lean, everyone has to be on the same page.

True

True or false: Just-in-time manufacturing helps to expose problems otherwise hidden by excess inventories and staff.

True

Which of the following is not an example of process waste? Transportation Defect-free products Inventory Defective products

Defect-free products

When considering a lean supply chain, which of the following components can have a lean focus? 1. Suppliers 2. Warehousing 3. Managers Only 2 and 3 Only 1 and 3 1, 2, and 3 Only 1 and 2

Only 1 and 2

In a lean system, who typically performs preventative maintenance? Operators Interns Management Executives

Operators

In a lean supply chain, which component includes automation for sourcing, bidding, and auctions? Procurement Manufacturing Customers Suppliers

Procurement

What information is shown in a value stream map? Multiple select question. Product flow Information flow Monetary flows Process information

Product flow Information flow

Which of the following is not a type of waste? Transportation Excessive processing Waiting time Respect for people

Respect for people

Which of the following are important components to a lean system? Multiple select question. Wages Suppliers Customers Employees

Suppliers Customers Employees

When designing a lean supply chain, what type of approach should be taken to integrate partners? Vertical Piece meal Systems Arms length

Systems

What is defined as anything that does not add value from the customer's perspective? Trash Waste Junk Excess

Waste

The _____ to produce or supply additional parts in a kanban pull system comes from downstream operations.

authority

Lean _____ utilizes group technology, quality at the source, and JIT production to support development of a lean supply chain.

concepts

Value stream mapping is used to show both the _____ state of a process _____as well as a possible state.

current future

When comparing service processes to manufacturing processes, one would say that they are _________ controllable. far more less equally more

less

A way to eliminate problems from making final assembly changes are by making all the changes at one time. changing suppliers often. making large changes as often as possible. making changes that are as small as possible.

making changes that are as small as possible.

Waste reduction is the ______________ of the value-adding activities and the _____________ of non-value-adding activities that are part of the value stream.

optimization; elimination

Kanban production control and minimized setup times are a part of the lean _____ _____principle.

production schedules

In both services and manufacturing, waste associated with defects can be reduced by improving _____.

quality

____ and a ____ response to changes are keys to success of a lean supply chain.

speed quick

The benchmark for lean manufacturing is known as the _____ _____ _____.

toyota production system

All of the following are types of waste in a lean process except waiting time. motion. product defects. underproduction.

underproduction.

When production flow is smoothed to dampen the schedule variation, we call this uniform plant loading. backflush. kanban system. level production.

uniform plant loading.

When determining the size of a kanban, which of the following do you need to consider? 1. Expected demand 2. Safety Stock 3. Size of Container 1, 2, and 3 1 and 3 only 1 and 2 only 2 and 3 only

1, 2, and 3

Question Mode Multiple Select Question Select all that apply The uniqueness of service delivery leads to which of the following sources of variation? Multiple select question. Quality of manufactured product Uncertainty in demand Uncertainty in task times Customers' role in production

Uncertainty in demand Uncertainty in task times Customers' role in production

Uncertainty regarding services can arise from which of the following? 1. Task times 2. Demand 3. Customer's role in production Only 2 and 3 Only 1 and 3 1, 2 and 3 Only 1 and 2

1, 2 and 3

Which of the following are signals that could be used in a kanban system? 1. Containers that identify the next production step 2. Cards to mark product movement 3. Colored golf ball Only 2 and 3 Only 1 and 2 Only 1 and 3 1, 2, and 3

1, 2, and 3

When designing a lean layout, the system designer must consider which type of logistics systems in regards to the plan? Internal External Internal and external This is not considered in lean design

Internal and external

To create a lean process, a full understanding of the _____ is required.

business

In a system using group technology, workers must be ___________ to run several machines and processes. patient flexible enough on-time highly skilled

flexible enough

Lean principles throughout the supply chain can primarily be seen in hiring practices of employers. less raw material usage. lower costs of wages. improved responsiveness to the customer.

improved responsiveness to the customer.

When vendors adopt _____ practices, incoming receiving inspections of their products can be bypassed.

quality

Which of the following is not a lean technique applied to service companies? Clarify process flows Develop supplier networks Eliminate housekeeping Eliminate unnecessary activities

Eliminate housekeeping

Which of the following is not a concept related to lean concepts in the supply chain? Collaboration with suppliers Specialized plants Generalized plants Building of a lean supply chain

Generalized plants

What served as the basis for lean thinking? SPC Inventory management Quality management JIT

JIT

What term is used to describe a philosophy that focuses on continuous improvement? Quality Kanban Kaizen Improvement

Kaizen

_____ bursts are specific, short-term projects designed to implement changes to a process.

Kaizen

In a _____ pull system, downstream operations provide the authorization for upstream production to occur.

Kanban

What term represents a signaling device to regulate flow? Kanban Backflush Backlog Fishbone

Kanban

When space is marked on the floor to identify where products should be stored, is an example of which type of kanban signal? Colored golf balls Container system Signal marker Kanban squares

Kanban squares

Which of the following would NOT be considered acceptable in the Toyota Production System? Providing employees with promotion opportunities Training employees to learn new skills Laying off employees when business is slow Working with employees to solve disputes

Laying off employees when business is slow

What type of production focuses on eliminating as much waste as possible? Lean Level JIT Customer focused

Lean

Which of the following is not a category that applies to lean design principles? Lean Transportation Lean concepts Lean Production Schedules Lean Supply Chains

Lean Transportation

True or false: Waste reduction refers only to the elimination of non-value-adding activities that are part of the value stream.

False

True or false: When comparing service processes and manufacturing, the same sources of variation cause waste.

False

True or false: When utilizing a quality at the source approach, employees do not have the authority to stop the process if there is a problem.

False

What term describes a philosophy in which similar parts are grouped into families, and the processes to make the parts are arranged into manufacturing cells? JIT production Group technology Lean layout Quality at the source

Group technology

In which part of a lean supply chain would you expect to see lean concepts applied to the movement of materials through the system? Warehousing Manufacturing Logistics Customers

Logistics

Which of the following is not a benefit of lean supply chains? Reduced obsolescence costs Lower employee wages Improved customer responsiveness Reduced inventory levels

Lower employee wages

Value stream mapping is a two-part process that details what? Past and future states Two proposed future states Current and future states Current and past states

Current and future states

Level production requires a stable schedule that requires which of the following: 1. Level scheduling 2. Freeze windows 3. Over utilization of capacity 2 and 3 1 and 2 1, 2 and 3 1 and 3

1 and 2

Under the traditional approach the optimal order quantity is _____, where under the kanban approach the optimal order quantity is _____.

6 2

Which of the following are guidelines to building a lean supply chain? Multiple select question. All firms along the value stream must make an adequate return on their investment relevant to the value stream. Every participating firm has the right to examine every activity in every firm relevant to the value stream. All firms should try and be the most profitable regardless of the impact to other firms along the value stream. All firms must work together to identify and eliminate waste.

All firms along the value stream must make an adequate return on their investment relevant to the value stream. Every participating firm has the right to examine every activity in every firm relevant to the value stream. All firms must work together to identify and eliminate waste.

In lean production, what is defined as something for which the customer is willing to pay? Waste Effectiveness Efficiency Customer value

Customer value

What term refers to the period of time during which the schedule is fixed and no further changes are possible? Backflush Freeze window Open window Moderately firm window

Freeze window

What are the three sets of principles related to supply chain design? Multiple select question. Lean shipping policies Lean production schedules Lean supply chain Lean concepts

Lean production schedules Lean supply chain Lean concepts

What type of schedule requires material to be pulled into final assembly in a uniform pattern? Level Chase Varied Even

Level

When conducting preventive maintenance, how often should inspection and repair be planned? Periodically Biannually Daily Annually

Periodically

What types of machines are best suited to lean operations? Advanced Complex Simple Large

Simple

An operation that is repeatable and standardized is a good candidate for Multiple select question. outsourcing. Six Sigma. lean production. process reengineering.

Six Sigma. lean production.

Which characteristics make an operation particularly well-suited to lean production and Six Sigma? Multiple select question. Standardized Chaotic Repeatable Uncertain

Standardized Repeatable

True or false: A lean layout requires a balanced work flow.

True

True or false: Backflush is used where the parts that go into each unit of the product are periodically removed from inventory.

True

True or false: Lean production uses a pull system for production.

True

True or false: Producing more than the required amount is considered waste in lean production.

True

True or false: Value stream includes both value-added and non-value-added activities.

True

What term describes the value-adding and non-value-adding activities required to design, order and provide a product or service? Value stream Flowcharting Product mapping Project management

Value stream

What is a special type of flowcharting tool that is used in lean processes? Production process mapping Value stream mapping Service blueprinting Process flowcharting

Value stream mapping

What type of activities transform materials and information into something the customer wants? Production scheduling Non-value adding activities Value-adding activities Service calls

Value-adding activities

Which of the following is not considered in lead time when calculating the number of kanbans needed? Time transporting materials to user Waiting time due to equipment breakdowns Waiting time while other materials are processed Processing time for the container

Waiting time due to equipment breakdowns

When you remove the number of component parts based upon the number of units produced, you are conducting a level schedule. cycle count. backflush. kanban.

backflush

The two core philosophies of the Toyota Production System are Multiple select question. increasing profits. elimination of waste. reducing capital investment. respect for people.

elimination of waste. respect for people.

Lean production requires that activities be __________________ to achieve production using minimal inventories. quick integrated separate close together

integrated

The acronym JIT stands for _____ _____ _____

just in time

Small specialized plants in lean supply chains are more important than plants that produce all of a firms products. large vertically managed facilities. medium facilities that produce almost all of a firms products.

large vertically managed facilities.

Reduced setup times are important because they lead to reductions in _____ size.

lot

Value stream mapping displays activities such as Multiple select question. lot size. labor costs. cycle time. percent uptime. changeover time.

lot size. cycle time. percent uptime. changeover time.

In a lean supply system, supply coordination must exist with the managers on different shifts. raw material supplier and the customer. needs of the production facilities. customer and the production facility.

needs of the production facilities.

Colored markers or cards are used in kanban production control systems to make the production floor more visually appealing. notify previous work centers that work is completed. notify the manager of which employee completed the work. notify upcoming centers of the work required.

notify upcoming centers of the work required.

A term used for the philosophy of making factory workers personally responsible for the quality of their output is quality at the source. six-sigma quality. customer value. respect for people.

quality at the source.

In the Toyota Production System, _____ for people is exemplified by providing opportunities and job security for employees.

respect

One way that hospitals have reorganized physical configuration with services is through the use of higher charges to increase revenue. through the use of lower cost outsourced providers. through the use of routing patients to multiple locations for treatments. through the use of more microclinics for specialty procedures.

through the use of more microclinics for specialty procedures.