Operations Ch 8

23) Quality at the source is a philosophy whereby defects are caught and corrected where they are created. True/False

True

25) Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called judoka. True/False

True

49) Some Kanban systems are set up without Kanban cards, and use the material containers or open spaces in a work area to withdraw materials. True/False

True

59) In the Toyota Production System, when a work station needs more material, it is obvious to both the worker and the supplier that material is needed. Further, the amount needed must be understood as well as the delivery time for replenishment. True/False

True

135) ________ is a methodology consisting of five workplace practices that are conducive to visual controls and lean production.

Five S

147) In a ________ system based on other Kanban signals, an empty bin signals a need to fill it.

container

130) Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called ________.

jidoka

39) One tactic of Total Preventive Maintenance (TPM) is to make workers responsible for routine minor maintenance of their own equipment. True/False

True

123) The Japanese term for continuous improvement in quality and productivity is ________.

Kaizen

2) Kaizen is the Japanese term for continuous improvement. True/False

True

88) The production of 300 units during a 480-minute work shift results in a takt time of: A) 300 seconds. B) 37.5 seconds. C) 120 seconds. D) 96 seconds.

D

31) A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 40 seconds. True/False

False

35) A five S program includes the activities of "simplify" and "system." True/False

False

38) Preventive maintenance is typically given very low priority in just-in-time systems. True/False

False

41) While lean systems work very well for manufacturing systems, they cannot be applied to service systems. True/False

False

117) Which of the following is a process consideration in the implementation of a lean system? A) Firms might have to change existing layouts. B) Workstations typically will have to be moved farther apart. C) A contract with strict job classifications will have to be adopted. D) Plant access by rail will become necessary.

A

69) Regarding the Eight Types of Waste that must be eliminated to implement lean systems, manufacturing an item before it is needed is part of which general waste category? A) Inappropriate Processing B) Waiting C) Inventory D) Overproduction

D

122) A system that organizes the resources, information flows, and decision rules that enable a firm to realize the benefits of JIT principles is the ________.

Just-in-time system, JIT system

76) There are many requirements for the successful implementation of the lean system of production. Which one of the following is not such a requirement? A) uniform assembly schedule B) short setup time C) low machine failure and low defects D) substantial natural resources

D

134) A ________ assembly line produces a mix of models in smaller lots.

mixed-model

110) Which of the following is NOT a part of value stream mapping analysis? A) steady state drawing B) current state drawing C) future state drawing D) work plan and implementation

A

112) Which of the following statements about the Toyota Production System is best? A) Toyota has built a learning organization over the course of 50 years. B) The key to success for Toyota is the set of tools and procedures readily apparent on a plant tour. C) The four principles that form the basis to TPS are impossible to replicate. D) Toyota has 23 manufacturing plants in North America alone.

A

113) The four bolts that hold the passenger seat in a pickup truck are tightened in a clockwise order beginning with the front right bolt in 24 seconds. This production factoid illustrates which of the following principles of the Toyota Production System? A) All work must be specified as to content. B) Every customer-supplier connection must be direct and unambiguous. C) The pathway for every service and product must be direct. D) Any improvements to the system must be made in accordance with the scientific method.

A

116) Which of the following is NOT a barrier for an organization when implementing a lean system? A) Workers usually feel as if they have gained autonomy. B) Workers can feel increased stress and pressure due to specified cycle times. C) Organizational relationships must be reoriented to build close cooperation and trust. D) The reward system might require tweaking.

A

119) When implementing a lean system: A) managers can mitigate some of the effects of worker stress by judiciously using safety stocks and emphasizing material flows rather than worker pace. B) management should base the reward system on production volume. C) the plant layout is the only environmental characteristic that need not be analyzed. D) it is critical to develop a master production schedule that changes frequently as forecasts change.

A

68) Regarding the Eight Types of Waste that must be eliminated to implement lean systems, which of the following statements is TRUE? A) Jobs with excessive motion should be redesigned. B) Work-in-process inventory is the direct result of underutilization of employees. C) Manufacturing an item before it is needed helps an organization detect and reduce defects. D) Product damage and deterioration result from using expensive high precision equipment.

A

71) What did the production manager say to the pile of scrapped material? A) "Hello muda." B) "Hello fadduh." C) "We need more kanbans." D) "JIT II Brute?"

A

75) The lean system concept will not work without the proper environment. Which one of the following characteristics is most common to firms that have successfully implemented a lean system? A) uniform assembly schedules B) specialized workforce C) high rates of machine failures D) longer setup times

A

83) The takt time of a process is defined as: A) the cycle time needed to match the rate of production to the rate of consumption. B) the total time required to move an item through a process. C) the time required to change a machine to run a new model. D) the lead time necessary to notify maintenance that a problem has occurred in an operation.

A

85) A takt time of 90 seconds generates a process output of: A) 40 units per hour. B) 30 units per hour. C) 4 units per hour. D) 90 units per hour.

A

94) "When in doubt, weed it out" describes which 5S element? A) Sort B) Straighten C) Shine D) Standardize

A

Case 8.3 Mike's Mustard Company uses a Kanban system to manufacture bulk mustard in gallon containers for restaurants. The demand for container lids over an eight-hour production day is 1000 units. The average waiting time for a container of lids is 45 minutes. The processing time for a container of lids is 2 hours, and a container holds 70 lids. 106) Use the information in Case 8.3. How many Kanban containers would be required if a 15% policy variable is used? A) 6 or fewer B) 7 or 8 C) 15 to 20 D) 20 or more

A

114) The rack at my assembly station that holds rear view mirrors is empty, so a runner wheels it away and replaces it with a new rack, fully populated with rear view mirrors. This production factoid illustrates which of the following principles of the Toyota Production System? A) All work must be specified as to content. B) Every customer-supplier connection must be direct and unambiguous. C) The pathway for every service and product must be direct. D) Any improvements to the system must be made in accordance with the scientific method.

B

120) The final assembly schedule in a lean system: A) should be developed for each product independent of the process requirements for the other products. B) strives to create a uniform flow at the work centers in the plant. C) avoids the use of small lot sizes because they create many production orders and cause confusion. D) allows daily changes in demand levels, regardless of size, to be incorporated immediately into the work center schedules.

B

64) Lean systems try to: A) produce a product in anticipation of demand. B) maximize the value added by of each of its activities. C) organize production in large lots to minimize the number of setups. D) reduce the labor content in all processes.

B

66) Regarding the Eight Types of Waste that must be eliminated to implement lean systems, excessive movement and material handling of product between processes is part of which general waste category? A) Motion B) Transportation C) Inappropriate Processing D) Underutilization of Employees

B

72) Companies using lean systems generally have: A) many suppliers to ensure that material shortages never occur. B) suppliers that are located nearby to decrease delivery lead time. C) suppliers that are willing to accept short-term contracts. D) suppliers who are low-cost producers.

B

77) Using customer demand to activate production of an item or service is called: A) the andon method. B) the pull method. C) the jidoka method. D) the push method.

B

82) In lean systems, if a defective product is found, which of the following is generally NOT done? A) The production line is stopped. B) The defective unit is passed on to the next workstation. C) The defective unit is returned to the worker responsible for creating the defect. D) The production line is made aware of the problem without necessarily stopping the line.

B

86) The production of 150 units during a 480-minute work shift results in a takt time of: A) 150 seconds. B) 192 seconds. C) 120 seconds. D) 18.8 seconds.

B

89) A takt time of 72 seconds generates a process output of: A) 72 units per hour. B) 50 units per hour. C) 60 units per hour. D) 80 units per hour.

B

91) Lean systems use the standardization of components because standardization: A) decreases the demand for each component. B) increases repeatability. C) allows for small lot sizes more easily. D) decreases repeatability.

B

93) "A place for everything, everything in its place" describes which 5S element? A) Sort B) Straighten C) Shine D) Standardize

B

99) Which one of the following statements is best? A) Two operating rules for the Kanban system are (1) the container size should be equal to at least seven days of supply and (2) each container must have a Kanban card. B) The Kanban system is more effective when the assembly schedule calls for small lots and does not fluctuate much from day to day. C) The number of Kanban cards should be equal to the desired safety stock times alpha. D) Supplier performance is much more important in U.S. environments than such factors as lot sizes, scrap losses, and worker flexibility.

B

Case 8.1 The Edward James Toy Company uses a Kanban system to make plastic wheels that are a component of several toys. The waiting time for a container of the wheels during production is 0.25 day; average processing time is 0.15 day per container. Each container holds 200 wheels. The company uses 2000 wheels a day in the production of its products. 101) Use the information in Case 8.1. Using a policy variable of 5%, calculate the number of Kanban containers needed for the wheels. A) three or fewer B) four or five C) five or six D) seven or more

B

Case 8.1 The Edward James Toy Company uses a Kanban system to make plastic wheels that are a component of several toys. The waiting time for a container of the wheels during production is 0.25 day; average processing time is 0.15 day per container. Each container holds 200 wheels. The company uses 2000 wheels a day in the production of its products. 102) Use the information in Case 8.1. How many Kanban containers would be required if a 10% policy variable is used? A) three or fewer B) four or five C) five or six D) seven or more

B

Case 8.3 Mike's Mustard Company uses a Kanban system to manufacture bulk mustard in gallon containers for restaurants. The demand for container lids over an eight-hour production day is 1000 units. The average waiting time for a container of lids is 45 minutes. The processing time for a container of lids is 2 hours, and a container holds 70 lids. 105) Use the information in Case 8.3. How many Kanban containers would Mike's Mustard require if a 5% policy variable is used? A) fewer than 2 B) 5 or 6 C) 50 to 650 D) 700 or more

B

100) Which one of the following statements regarding the Toyota production system is best? A) It is particularly well suited for making irregularly used parts and customized "specials." B) It is a "push system," with orders pushed out in anticipation of future requirements. C) Each container has either a withdrawal or production-ordering Kanban. D) It does not use poka yoke or 5S practices.

C

115) Implementing a lean system: A) has the advantage that workers have less stress because of the routine, repetitive work they perform. B) typically relieves the workers and first-line supervisors from activities such as scheduling, expediting, and productivity improvements. C) requires an examination of the reward system to make sure it is consistent with the JIT philosophy. D) involves the reorganization of material flows to that of a flexible flow.

C

118) Which one of the following is an advantage of lean systems? A) Lean systems reduce equipment needs by using larger lot sizes. B) Lean systems can be implemented in any production environment. C) Lean systems result in a decrease in safety stock and work-in-process inventory. D) Lean systems result in an increase in manufacturing lead times.

C

67) Regarding the Eight Types of Waste that must be eliminated to implement lean systems, using expensive high precision equipment when a simpler machine would suffice is part of which general waste category? A) Motion B) Overproduction C) Inappropriate Processing D) Defects

C

70) Continuous improvement with lean systems: A) involves navigating a ship over treacherous rocks. B) requires periodically increasing lot sizes or workforce levels to uncover problems. C) entails systematically stressing the system and focusing on problem areas. D) focuses exclusively on internal operations without addressing relationships with customers and suppliers.

C

73) Lean systems maintain inventory in small lot sizes because small lot sizes: A) increase pipeline inventory, allowing the organization to buffer against demand uncertainties. B) increase the quality level of the product. C) enable schedules to use machine capacities more efficiently. D) increase manufacturing lead time because of the increase in waiting time.

C

79) Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known as: A) andon. B) muda. C) jidoka. D) poka-yoke.

C

81) Items to be assembled that fit together only the proper way are an example of: A) andon. B) jidoka. C) poka-yoke. D) muda.

C

84) The production of 240 units during a 480-minute work shift results in a takt time of: A) 24 seconds. B) 30 seconds. C) 120 seconds. D) 240 seconds.

C

87) A takt time of 1.25 minutes generates a process output of: A) 75 units per hour. B) 20.8 units per hour. C) 48 units per hour. D) 80 units per hour.

C

90) Justin Thyme used to run one batch each of 500 As, 300 Bs and 100 Cs every month but now he runs a batch of 5 As, 3 Bs, and 1 C every half day: A) thanks to his employer's move away from single-digit setups. B) now that he has andon lights installed at the appropriate work centers. C) now that he embraces mixed-model assembly. D) in order to increase muda.

C

95) Combining parts or products with similar characteristics into families and setting machines aside for their production is known as: A) the one-worker, multiple machines (OWMM) method of production. B) the standardized component method of manufacturing. C) group technology. D) the flexible workforce approach to manufacturing.

C

96) Management at Pepman has decided to switch from a push system to a pull system of manufacturing. They are a large repetitive manufacturer of bicycles. Which one of the following is most likely to occur? A) The cycle time will increase, resulting in higher inventory levels. B) The space required will increase due to the increase in the number of units that require rework. C) The decrease in WIP inventory levels will reduce the space requirements. D) The workers at any given process will produce units before they are needed by the subsequent process.

C

97) A Kanban system is an important mechanism for lean system management. Which one of the following statements regarding the operation of a Kanban system is best? A) A typical Kanban used in the JIT system includes information such as item number, unit price, competitor's product name, and its price. B) A Kanban can be used to set the order quantity but not the inventory level. C) A Kanban and a container move as a pair once production begins at the fabrication process. D) An empty container can be exchanged for a full container at the storage location even though no Kanban is on the full container.

C

Case 8.2 The Jewel Golf Club Company, which recently began using a Kanban system, has had problems with high inventory levels of one of the handle grips used to make several versions of its clubs. Daily demand for the grip is 3000 units, average waiting time during production is 0.20 day, processing time is 0.10 day per container, and a container holds 150 grips. 103) Use the information in Case 8.2. How many Kanban containers would Jewel require if a 5% policy variable is used? A) three or fewer B) four or five C) six or seven D) eight or more

C

Case 8.3 Mike's Mustard Company uses a Kanban system to manufacture bulk mustard in gallon containers for restaurants. The demand for container lids over an eight-hour production day is 1000 units. The average waiting time for a container of lids is 45 minutes. The processing time for a container of lids is 2 hours, and a container holds 70 lids. 107) Use the information in Case 8.3. How many Kanban containers would Mike's Mustard require if the containers held only 15 pieces and a 5% policy variable is declared? A) 10 or fewer B) 11 to 20 C) 21 to 30 D) 31 or more

C

108) Which of the following actions would increase the number of containers in use in a Kanban system? A) using larger containers that can hold more parts than before B) less demand for the part held by the container C) faster processing times for the part held by the container D) increased waiting time for the container

D

109) Which of the following actions would decrease the number of containers in use in a Kanban system? A) smaller containers that can hold fewer parts than before B) higher demand for the part held by the container C) increased waiting time for the container D) faster processing times for the part held by the container

D

111) Which of these is NOT a so-called "hypothesis principle" of the Toyota Production System? A) All work must be specified as to content. B) Every customer-supplier connection must be direct and unambiguous. C) All workers must be guaranteed full employment for life. D) Any improvements to the system must be made in accordance with the scientific method.

D

65) The just-in-time (JIT) system is a(n): A) management system of people and procedures to fulfill all delivery deadlines. B) production system of small-lot manufacturing to reduce work-in-process inventory. C) materials management system for removing all inventories. D) integrated system of managing resources, information, and decision processes to eliminate waste.

D

74) The goal of single-digit setups is to have a setup time: A) of less than one shift. B) of less than one hour. C) of less than 30 minutes. D) of less than 10 minutes.

D

78) A method in which production of an item begins in advance of customer needs is called: A) the andon method. B) the pull method. C) the jidoka method. D) the push method.

D

80) Mistake-proofing is known by the term: A) andon. B) muda. C) jidoka. D) poka-yoke.

D

92) Weeding out unnecessary items, neatly arranging what's left, and cleaning the work area are components of: A) a Kanban system. B) a constraint management system. C) mixed-model assembly. D) a 5S program.

D

98) An important mechanism for lean systems is a Kanban system. Which one of the following statements correctly describes the behavior of a two-card Kanban system? A) A withdrawal Kanban is issued to authorize production in the fabrication process. B) A production-ordering Kanban authorizes the assembly process to remove the materials from the storage location. C) The fabrication process produces certain units defined by the lot size and pushes them down to the assembly process. D) Containers must never be removed from the storage location without an authorizing withdrawal Kanban.

D

Case 8.2 The Jewel Golf Club Company, which recently began using a Kanban system, has had problems with high inventory levels of one of the handle grips used to make several versions of its clubs. Daily demand for the grip is 3000 units, average waiting time during production is 0.20 day, processing time is 0.10 day per container, and a container holds 150 grips. 104) Use the information in Case 8.2. How many Kanban containers would Jewel require if a 10% policy variable is used? A) three or fewer B) four or five C) five or six D) six or seven

D

11) The goal of single-digit setup is to have a setup completed in fewer than 10 hours. True/False

False

14) While overproduction creates an item before it is needed, the extra time before an item is needed makes it easier to detect defects and reduce their impact on a process. True/False

False

16) Using expensive, high precision equipment, even when simpler machines would suffice, is encouraged when lean systems are implemented, because this is the only way high quality manufacturing can be achieved. True/False

False

19) Push systems are often used in firms with highly repetitive processes and well defined work flows of standardized items. True/False

False

20) The pull method begins the production of an item in advance of customer needs. True/False

False

22) Just-in-time (JIT) systems rely on inspectors to inspect quality into the product. True/False

False

24) Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called heijunka. True/False

False

27) The Japanese practice of andon means that production does not begin until a card or bin is empty. True/False

False

29) Takt time is the cycle time needed to maximize utilization of an organization's workers and equipment. True/False

False

3) In a lean system, large inventories are not considered a type of waste, because they prevent operator wait times. True/False

False

45) An OWMM arrangement reduces labor requirements but increases inventory. True/False

False

48) In a Kanban system, materials may be withdrawn without a withdrawal card if the operation requiring the material is about to run out of work. True/False

False

5) Manufacturing an item before it is needed in a lean system is not considered waste, because it helps keep material flowing through the system. True/False

False

50) As the average processing time per container of parts increases, fewer containers are needed in a Kanban system. True/False

False

52) The value stream mapping tool often requires completion of the future state drawing before the current state drawing, to help managers see the future state goals and more easily identify problems with the current state of the process. True/False

False

54) Often in value stream mapping, analysts must rely on process information from shop floor workers rather than direct observation in an effort to quickly develop a work plan and accelerate implementing the improved process. True/False

False

56) A value stream map shows the flows of materials and information and the lines of responsibility and authority. True/False

False

57) After the earthquake and tsunami of 2011, Toyota's suppliers and plants were able to maintain production levels due to their efficiency. True/False

False

58) Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving. True/False

False

61) In the Toyota Production System, services and goods flow to the next available person or machine to maintain smooth, rapid flow. True/False

False

62) One big advantage of lean systems is that they can usually be put in place without any major changes to existing layouts. True/False

False

63) Lean systems do not need stable master production schedules. True/False

False

9) If infrequent, large shipments of purchased items are arranged with suppliers, large inventory savings for these items can be realized. True/False

False

144) ________ is the combining of parts or products with similar characteristics into families and setting aside groups of machines for their production.

Group technology (GT)

133) ________ is the leveling of production load by both volume and product mix.

Heijunka

124) ________ refers to a form of supplier partnership that places a supplier representative, who is empowered to plan and schedule the replenishment of materials from the supplier, in the customer's plant on a full-time basis.

JIT II

121) ________ is the philosophy that waste can be eliminated by cutting unnecessary inventory and removing non-value-adding activities in operations.

Just-in-time, JIT

145) A ________ is a card used to control the flow of production through a factory.

Kanban

138) ________ are operating systems that maximize the value added of each of their activities by paring unnecessary resources and delays from them.

Lean systems

131) ________ refers to mistake-proofing methods aimed at designing fail-safe systems that minimize human error.

Poka-yoke

126) ________ refers to the goal of having a setup time of fewer than 10 minutes.

Single-digit setup

151) ________ is a graphic representation of the Toyota Production System showing all of the essential elements of lean systems that make the TPS work well.

The House of Toyota

137) ________ practices include early testing of machine parts that may need to be replaced and making workers responsible for routine minor maintenance of their own equipment.

Total Preventive Maintenance, TPM

1) The just-in-time (JIT) philosophy is the belief that cutting inventory and removing non-value-added activities in operations can eliminate waste. True/False

True

10) JIT II refers to a form of supplier partnership that places a supplier representative, who is empowered to plan and schedule the replenishment of materials from the supplier, in the customer's plant on a full-time basis. True/False

True

12) In lean systems, the need for single-digit setups is driven by the desire for small lot sizes. True/False

True

13) In a lean system, excess inventory hides problems on the shop floor, and thus prevents sources of waste from being identified and eliminated. True/False

True

15) In lean systems, work-in-process inventory is a direct result of overproduction and waiting. True/False

True

17) Long production runs, poor material flows, and processes that are not tightly linked to one another can cause over 90% of a product's lead time to be spent waiting. True/False

True

18) The push method begins the production of items in advance of customer needs. True/False

True

21) Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method. True/False

True

26) A power cord that can be plugged in only one way is an example of a poka-yoke. True/False

True

28) Takt time is the cycle time needed to match the rate of production to the rate of sales. True/False

True

30) A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 90 seconds. True/False

True

32) Heijunka is the leveling of production load by both volume and product mix. True/False

True

33) Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots. True/False

True

34) Productivity tends to increase when components are standardized because each worker performs a standardized task or work method more often each day. True/False

True

36) Five S practices can enable workers to visually see everything differently, prioritize tasks, and achieve a greater degree of focus. True/False

True

37) Five S practices can be applied to both manufacturing and service settings and can include offices, work spaces, tool rooms, and shop floors. True/False

True

4) In a lean system, wait times can be caused to some extent by long production runs. True/False

True

40) Lean systems are operating systems that maximize the value added of each of its activities by paring unnecessary resources and delays from them. True/False

True

42) One benefit of a lean system is that it reduces space requirements. True/False

True

43) Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families. True/False

True

44) A one-person cell in which a worker operates several different machines simultaneously to achieve a line flow is called a one-worker, multiple-machines (OWMM) cell. True/False

True

46) Group technology collects similar parts into families and organizes machine tools into separate cells. True/False

True

47) A Kanban is a card used to control the flow of production in many just-in-time systems. True/False

True

51) Use of value stream mapping requires construction of a current state drawing, a future state drawing, and an implementation plan. True/False

True

53) To complete the current state drawing of a process, a map of the current situation is developed, including such items as material and information flows, process times, setup times, batch sizes, scrap rates, and number of people required. True/False

True

55) The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints, while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities. True/False

True

6) In service systems, a common approach used to stress the system and identify problems is to reduce the number of employees doing an activity until the process begins to slow or come to a halt. True/False

True

60) The Toyota Production System requires that any process improvements are to be made at the lowest level of the organization. True/False

True

7) In manufacturing systems, one way to achieve continuous improvement can be to maintain low inventories, and periodically cut safety stocks almost to zero. True/False

True

8) Just-in-time (JIT) systems need close relationships with suppliers. True/False

True

148) In a ________ system based on other Kanban signals, an empty space signals a need to fill it.

containerless

142) In the Toyota Production System, all work must be completely specified as to ________, ________, ________ and ________.

content, sequence, timing, outcome

150) Value stream maps consist of a(n)________, a(n)________, and a(n)________.

current state drawing, future state drawing, implementation plan

139) All improvements to the Toyota Production System must be made at the ________ level.

lowest

143) A ________ is a workstation in which a worker operates several different machines simultaneously to achieve a line flow.

one-worker, multiple-machines (OWMM) cell

129) The ________ method activates production of a service or item based on customer demand.

pull

128) The ________ method produces the item in advance of customer need.

push

140) All improvements to the Toyota Production System must be made using the ________ method.

scientific

125) A(n) ________ is a group of activities needed to readjust a process between successive lots of items.

setup or changeover

127) If the inventory advantages of a lean system are to be realized, small lot sizes must be used; in order to use small lot sizes, manufacturers must significantly reduce ________ .

setup times

141) The pathway for every service and product in the Toyota Production System must be ________ and ________.

simple, direct

136) The list of five S practices includes ________, ________, ________, ________ and ________.

sort, straighten, shine, standardize, sustain

132) A lean system's ________ refers to the cycle time needed to match the rate of production to the rate of sales or consumption.

takt time

146) A ________ is based on both a withdrawal card and a production-order card, to control inventory quantities more closely.

two-card Kanban system

149) ________ is a qualitative lean tool for eliminating waste that involves current state and future state drawings, and an implementation plan.

value stream mapping