Supply Chain 8: Lean System

True or false: Every operational setting and business sector implements the same level of lean systems in application and practice.

False In actual practice, different sectors have adopted lean in different levels. Some do not use lean, others have heavily adopted it and achieve greater competitive advantage. False

____ ______ makes current performance and potential problems immediately visually apparent.

visual control

_____ works to identify and prevent all possible equipment breakdowns.

Total productive maintenance

_____ organizes operations systems by grouping together similar customers and then designing and implementing product systems to serve these specific customers.

focused factory

is the application of lean principles and tools to the task of designing products.

lean design

The ____ _____approach is a philosophy that emphasizes the minimization of the amount of all resources used in the various activities of an enterprise.

lean systems

Identify the benefits of lean systems. (Check all that apply.)

A firm can significantly lower its break-even production quantity. Lean systems lower the variable production costs associated with labor, materials, and energy. Lean systems raise the unit profitability of products.

Identify the prescriptions that the application of lean principles to supply chain relationships leads to. (Check all that apply.)

Buy to achieve the lowest total cost. Work with suppliers and not against them. Treat problems as a symptom and focus on the factors that contributed to the emergence of that problem. Keep distances between partners short. Minimize the number of suppliers.

Identify the benefits of the application of the lean systems approach across the supply chain. (Check all that apply.)

In stable environments, lean can enhance the performance of the supply chain. Suppliers and customers better understand each other's needs and capabilities. Application of lean approach leads to improved quality, reduced costs, and improved customer service.

Identify the true statements about Kaizen Events. (Check all that apply.)

In this process, cross-functional team members document a process, assess the performance, and develop and document the implemented process changes. They are completed in less than a week.

Match the different types of wastes (in the left column) with their respective definitions (in the right column).

Overproduction- processing more units than needed Waiting- resources wasted waiting for work Transportation- units being unnecessarily moved Processing- excessive or unnecessary operations Inventory- units waiting to processed or delivered Motion- unnessary or excessive resource activity Product defects - waste due to unnecessary scrap, rework, or correction

identify the true statements about the application of lean systems within a firm. (Check all that apply.)

The lean approach requires tight coordination of marketing, sales, and operations to increase communication and decrease order processing lead times. Self-motivated employees who have a strong interest in solving problems through process innovation must be hired. The design of training programs needs to be driven by lean objectives.

True or false: The essential goal of SPC (statistical process control) is to put controls in place that help ensure the quality of production and give quick notice when unusual events occur that might lead to product or service defects.

True

Identify the true statements about total productive maintenance (TPM). (Check all that apply.)

Typical TPM programs emphasize shop floor organization. A TPM program requires disciplined adherence to operating procedures and rigorous equipment design and upkeep. In addition to manufacturing equipment, TPM can be applied to computer networks and automated service kiosks.

Identify the examples of visual controls. (Check all that apply.)

bulletin boards SPC charts large electrionic displays lighting systmes Andon boards

.Match the types of events causing problems for lean supply chains (in the left column) with their respective examples (in the right column).

operational/Technological- forecast errors, capacity constraints, and IT disruptions social- labor strikes and sabotage natural/hazard- fire, flood, monsoon, and earthquake economy/competition- interst rate fluctuations and bankruptcy of supply partners legal/political- lawsuits , wars, border customs, and regulations

_____ is an emphasis on redesigning processes in such a way as to make mistakes either impossible or immediately apparent to the worker.

poka-yoke

_____ is the practice of eliminating defects at their root cause origination points.

quality at the source

Identify the major goals of lean design. (Check all that apply.)

Design products that support corporate strategic objectives. Design products that exactly meet customers' needs. Design products that reduce/minimize the opportunities for waste.

Define process analysis/value stream mapping.

It is a graphical technique that helps managers understand material and information flows as a product makes its way through the process.

Define single minute exchange of dies

It is a systematic three-stage approach procedure for reducing long setups.

Identify the true statements about group technology.

It is also called cellular manufacturing. In group technology, part families are created based on the similarities in design features.

_____ is a scheduling system that builds output in response to actual customer demand.

Kanban scheduling

Match the different focused factories (in the left column) with their respective description (in the right column).

Market-focused supplying a range of products to customers with similar or complementary demand patterns and value propositions Product-focused producing products that have similar technological processing requirements

Match the important principles of lean systems (in the left column) with their respective descriptions (in the right column).

Precisely specify value for each specific product - The final consumer ultimately determines the value of a product or service. Identify the value stream for each product -A firm must clearly understand and link together all of the activities involved in product development, order processing, production, and delivery. Make value flow without interruptions -The movements of materials and information in value streams should be swift and even. Let the customer pull value from the producer -Activities in operating processes should be initiated by actual customer demands not by schedules that are based on forecasts. Pursue perfection -Continuous improvement is always possible.

Match the activities of a 5-S program in English (in the left column) with their corresponding Japanese words (in the right column). Match the activities of a 5-S program (in the left column) with their respective intent (in the right column).

Sort- seiri red tag suspected unnecessary items. after a monitoring period, throw out unnecessary items straighten- seiton put everything in an orderly fashion so that it can be located. scrub-seiso Clean everything and eliminate the sources of dirt. systematize- seiketsu make cleaning and checking routine. Set the standard, train and maintain. standarize- shitsuke standarize the previous four stpes Continuously improve processes and use visual control through performance boards, checklists, and graphs.

_____ uses various statistical tools to analyze the capabilities of a given process and monitor its performance with the goal of flagging potential problems before they occur.

Statistical Process Control (SPC)

Identify a scheduling approach aimed at synchronizing the output rate with the rate of customer demand.

TAKT time flow balancing

A firm works a 40 hour week to process 4000 customers' orders, but processes only 50 orders per hour. The firm tries to bring up their output rate to 100 orders per hour to meet the customer demand. Which of the following does this scenario illustrate?

TAKT time flow balancing is a scheduling approach aimed at synchronizing the output rate with the rate of customer demand. In this scenario, the firm is adjusting its output rate to match the rate of customer demand.

Identify the lean systems tools that are used for operational scheduling and control. (Check all that apply.)

TAKT time flow balancing Kanban (pull) scheduling mixed model scheduling setup reduction visual control statistical process control

In _____, activities are initiated and products are moved according to a schedule, irrespective of whether or not a customer demands it.

a push scheduling

Identify the different terms used for poka-yoke. (Check all that apply.)

fail-safing mistake-proofing

_____ is an approach to work layout and scheduling that gathers in one location all of the equipment and work skills necessary to complete production of a family of similar products.

group technology

Level, mixed-model scheduling is also known as

heijunka

Identify the methods by which lean systems can lower the break-even production quantity of a firm. (Check all that apply.)

increasing the contribution margin reducing rixed overhead costs

_____ focuses on developing technological features of equipment and processes that automatically detect and flag problems.

jidoka

Identify the different terms used to describe lean systems. (Check all that apply.)

jut-in-time (JIT) manufacturing stockless production zero inventories Toyota Production Systems (TPS) lean production

_____ is the practice of leveling quantities of different product models produced over a period of time, with the goal of reducing batch sizes and lead times.

level, mixed- model scheduling, heijunka

Identify the lean systems tools that are used for continuous process improvement. (Check all that apply.)

quality at the source Kaizen Events Process analysis/ Value stream mapping Poka-yoke (fail-safing/mistake-proofing) 5-S program Simplification/Standardization Digital Lean

___ ____is the process used to reduce setup and changeover times with the goal of making the output of smaller batches more efficient.

setup reduction

In lean systems, _____ focuses on eliminating non-value-added activities in a process.

simplification

In lean systems, _____ is aimed at clarifying and documenting the steps in a process so that they are executed exactly the same way every time by every worker.

standardization

Identify the lean systems tools that are used for development of facilities and resources. (Check all that apply.)

total productive maintenance group technology focused factories