oscm 14
What is the most important organizational/cultural aspect without which Lean implementation is doomed?
A spirit of cooperation and mutual respect among management, employees, vendors
Select the best definition of Value Stream Mapping.
A visual tool to systematically analyze the flow of materials and information involved in bringing a product or service to a customer
The success of a lean system relies heavily on which of the three items that follow?
Achieving a lean thinking culture Leadership commitment Effective teamwork
In Lean terminology waste refers to what?
Any aspect of a process which is non-value added
What are the two parts of Autonomation, a Lean quality improvement technique?
Defect detection and work stoppage
Which of the following is not a benefit of lean systems?
Economies of scale
All of the following are benefits of a limited work-in-process system EXCEPT _______.
Ensures uniform customer demand
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
What are some of the benefits of cross-training workers, a personnel management method often used in a Lean organization? (Select all the reasons that apply.)
Helps with system bottlenecks for line balancing purposes Adds flexibility when a co-worker is absent
All of the following are benefits of the 5S Lean "housekeeping" system except which?
Increased risk of accidents
How do small lot sizes support Lean process design? (Select all correct answers.)
Inspection and rework costs are less Work-in-process inventory is reduced More flexibility to meet customer demand
Identify the true statements about Kanban. (Select all that apply.)
It requires workers to signal when they have run out of parts at their assembly operation. It replaces material or parts only when needed, so as to avoid overproduction.
Autonomation, a quality improvement technique, is known by what Japanese word?
Jidoka
Which of the following accurately explains the difference between kanban and CONWIP (constant work-in-process) as methods for controlling WIP?
Kanban signals work to move when the next work station is ready. In CONWIP a unit enters the system only when a unit exits.
In order to achieve a balanced, rapid flow through a Lean system, disruptions must be minimized. What are some causes of disruptions in production? (Select all that apply.)
Late deliveries from suppliers Equipment breakdowns Quality problems
Which of the following statements is true about Lean Manufacturing?
Lean Manufacturing started in Japan at Toyota.
How is Lean different from Six Sigma?
Lean focuses on eliminating waste, improving flow while Six Sigma reduces variability.
In what ways does JIT (Just-In-Time) impact the supply chain? (Select all correct answers.)
Loading docks busier from more frequent orders Suppliers are under pressure to deliver on-time Vendors may charge more per unit for smaller shipments
In order to make a JIT/Lean system flexible to handle a variety of products, what two things must be reduced?
Long setup/changeover times and long lead times from vendors
When converting to Lean/Just-in-time operations what are workers usually most concerned about?
Loss of their job as production efficiency increases
What are some of the benefits of Lean Operations?
Lower costs, greater productivity, higher quality
Which of the following statements is correct about planning a successful conversion to Lean/Just-in-time operations.
Management and employees must be convinced of benefit and receive training prior to conversion to avoid obstacles.
What is the most serious obstacle to Lean conversion?
Management commitment of resources required for conversion
Value Stream Mapping is a technique that originated at Toyota, where it was referred to as _____.
Material and Information Flow Mapping
How does setup time reduction contribute to Lean process design?
Smaller lot sizes mean more setups (changeovers of equipment). Smooth, rapid flow is the goal.
What are the two common threads across all the building blocks of Lean/JIT systems.
Speed and Simplicity
A Six Sigma process is under what kind of control?
Statistical process control
What are some of the major obstacles encountered when converting to Lean/Just-in-time operations from traditional methods? (Select all that apply.)
Suppliers may resist for various reasons--frequent deliveries, burden of quality, etc. The organization's culture may not be compatible with the Lean philosophy. Management may resist because Lean shifts some of their responsibilities to workers.
Select the best definition of takt time, which is used in Lean process design to balance workload.
The cycle time needed to meet the demand rate
The acronym WIP stands for what?
Work-In-Process
In a Lean organization workers are treated as assets. What does this mean in a lean organization? (Select all the examples that apply.)
Workers are well-trained in Lean philosophy and methods. Workers are given authority to make decisions that effect their work.
In Lean/JIT systems the burden of ensuring quality of production inputs from vendors shifts from the _____________ to the _______________.
buyer/seller
Direct suppliers must be able to support _____ just-in-time deliveries of _____ of parts.
frequent, small batches
All of the following are benefits of a limited work-in-process system EXCEPT _______.
greater cycle time variability; WIP = cycle time x arrival rate
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 _____.
individual workstation, the system as a whole
In Lean process design what is the ideal lot size in numbers of units?
1
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.
6 minutes per cycle
Select the best definition of Lean Operations.
A flexible system of operations using fewer resources than a traditional system
Select the four building blocks which support the goals of Lean/Just-in-Time systems from the following list:
Personnel & organization elements Manufacturing, planning and control Process design Product design
Select the best definition of level loading.
Producing at the same rate or quantity each day (e.g., 100 units of A, B, C each day with constant ratios)
Which of the below statements best describes the difference between a push and pull system of production?
Push: work is sent to the next operation upon completion. Pull: the subsequent operation takes from the preceding.
What characteristic of lean systems enables equipment flexibility and output variety without disruption in a lean system?
Quick changeovers
Which of the following attributes are characteristics of lean systems? (Select all that apply.)
Quick changeovers Waste reduction Continuous improvement
The benefits of Lean are most easily realized in which Process type?
Repetitive assembly
Which of the following is an example of standardized parts supporting Lean.
Same hard drive casing is used in all Dell Computers so assembler learns how to install one part number across all models of computers.
Single minute exchange of die (SMED) is a system developed at Toyota for reducing what?
Setup time
When services adopt Lean operations what is usually the main focus of improvement?
Time to perform a service
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
Which of the following is an example of "elimination of disruptions" for Lean services. (Select the best answer.)
Try to avoid having workers who are servicing employees also answer telephones
JIT II is also known by what other acronym?
VMI (Vendor Managed Inventory)
Select the best definition of JIT II.
Vendors manage inventory on Buyer's premises
At Toyota Lean Manufacturing is focused on Waste Reduction in every aspect of process. What is meant by "waste" in this context?
Waste is anything that does not add value to or interferes with production.
The 5W2H approach to process improvement is a simple and effective method. What does 5W2H stand for?
What, Why, Where, When, Who, How, How Much?
