OPs Smartbook ch 8

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? Multiple choice question. A and B A and C B and C

A and C

Which production schedule for products of type A and B is a result of production leveling? Multiple choice question. ABABABABABABABAB AAAABBBBAAAABBBB

ABABABABABABABAB

Match the situation with the likely improvement method. Demand-constrained: Supply-constrained: Increase flow rate Reduce costs

Demand-constrained: Reduce costs Supply-constrained: Increase flow rate

Which source of waste is the most visible form of supply-demand mismatch? Overprocessing Transport Waiting Inventory

Inventory

Which term refers to shutting down a machine upon detection of a problem? Multiple choice question. Kanban Ikko-nagashi Kaizen Jidoka

Jidoka

______ is the process control system wherein an upstream resource replenishes what demand has withdrawn from the downstream. Multiple choice question. Single-unit flow Make-to-order Kaizen Kanban

Kanban

Which source of waste is involved when a worker spends unnecessary time converting an input flow unit to an output? Multiple choice question. Waiting Overproduction Overprocessing Unnecessary motion and movements

Overprocessing

Which principle of operational excellence refers to a long-term approach that favors quality and capabilities over short-term financial goals ? Problem solving Processes Philosophy People and partners

Philosophy

Upon discovering a defect, which of the following actions would represent the TPS philosophy of quality? (Check all that apply.) Multiple select question. Keep production running until the cause of the defect is determined Pull a cord that stops the production line immediately. Thoroughly analyze the root cause of the problem. Ask the centralized Quality Control department to address the problem.

Pull a cord that stops the production line immediately. Thoroughly analyze the root cause of the problem.

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

Resources that are ____________ to each other in the process flow diagram should also be co-located in physical space.

close

High inventory levels tend to ______ quality problems. Multiple choice question. cover up expose

cover up

One factor when designing a Kanban system is the ______ rate. Multiple choice question. demand supply

demand

Inventory is controlled in a Kanban system because production occurs at an upstream resource only when it has an ____________ container.

empty

True/False: Taylor viewed the factory floor worker as an asset who could assist with the design of efficient work and promises.

false; Taylor believed that engineers should design the work that factory floor workers did

True or false: In a Kanban system, there is no limit on how much inventory can accumulate.

false; in a kanban system inventory is limited by how much is authorized by the kanban cards

True or false: Value-add time is always the same as processing time.

false; not all processing time is value-added

When designing a Kanban system, the larger the container size, the ______ Kanban cards are needed. Multiple choice question. more fewer

fewer

A benefit of the U-shaped line is that it allows for more worker ______. Multiple choice question. idle time flexibility isolation specialization

flexibility

Imagine a process with four steps and one individual working at each step. Which workforce would be preferable based on the TPS philosophy toward pace? Multiple choice question. Three novice workers and one expert Four novice workers

four novice workers

The longer the replenishment time, the _____ the number of Kanban cards. Multiple choice question. lesser greater

greater

The basic philosophy of TPS is that the production process should ______ production when a quality problem is discovered. Multiple choice question. continue halt

halt

The higher the labor content, the ______ the target manpower. Multiple choice question. higher lower

higher

The more available time, the ______ the takt time. Multiple choice question. lower higher

higher

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

increase

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

inventory

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

inventory

The Japanese word ___________________describes the actions of detecting quality problems, stopping the process, and alerting the operator.

jidoka

The Japanese word __________________ describes the process of analyzing the root cause of a quality problem on the shop floor.

kaizen

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

The higher the demand rate, the ______ the takt time. Multiple choice question. higher lower

lower

The higher the takt time, the _____ the target manpower. Multiple choice question. higher lower

lower

U-shaped lines facilitate one worker being in charge of _______ machine. Multiple choice question. one more than one

more than one

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

muda

___________ is a Japanese word that refers to an overburdening of workers or equipment.

muri

The difference between labor content and flow time is ______ time. Multiple choice question. value-added non-value-added

non-value-added

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

order

How should items be transported in order to implement single unit flow? Multiple choice question. All at once By outsourced workers In batches Piece-by-piece

piece-by-piece

High inventory and ______ quality go hand in hand. Multiple choice question. poor documented improving good

poor

To minimize distance, processes should be laid out so the physical lay-out reflects the _________________ flow.

process

Which principle of operational excellence refers to continuous process flows that match supply with demand? Multiple choice question. People and partners Problem solving Philosophy Processes

processes

The P in TPS stands for

production

A one unit flow requires executing a _____ system. Multiple choice question. push pull

pull

In a _____ system, inventory is a managerial decision. Multiple choice question. pull push

pull

In a _____ system, inventory is a managerial decision. Multiple choice question. push pull

pull

In which type of system does production occurs only because there is demand? Multiple choice question. TPS Pull Push Flow cycle

pull

Which type of system is needed to implement single unit flow? Production Push Pull Partner

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. pull push

push

Which type of system allows inventory to keep accumulating? Multiple choice question. Kanban Pull TPS Push

push

Which factor should govern the speed of a process? Multiple choice question. Discretionary flow of its resources Speed of fastest workers Rate of demand Demands of investors

rate of demand

Idle time is a waste of a ____________ time.

resources

Two forms of waste are waste of a flow unit's time and waste of a _____________ time.

resources

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

safety

For __________________ , workers were animals who needed to be trained to perform work in the manner designed by engineers. Taylor Ohno

taylor

Reducing the flow _____ improves the extent to which we consider an operation lean.

time

One way to determine where a flow unit's time is wasted is to take the perspective of the flow unit and create a ________. Multiple choice question. process flow diagram time line

time line

The term lean was coined based on a study of the success behind the __________________ Production System.

toyota

A one unit flow often requires a facility layout to reduce the need for _______________ batching.

transport

True or false: A Kanban system typically controls the amount of inventory.

true; the inventory can never exceed how much is authorized by the cards

Mura refers to a(n) ____________ workflow.

uneven

Which source of waste is involved when a worker performs a task in a way that has not been optimized? Multiple choice question. Waiting Rework Inventory Unnecessary motion and movements

unnecessary motion and movements

Ideally, the time a flow unit spends in processing is _______ time. Multiple choice question. value-added wasted

value-added