Test Bank Chapter 16 Lean Systems - Operations Management 2e Canadian Test Bank by Roberta S. Russell. DOCX document preview.
CHAPTER 16
LEAN SYSTEMS
CHAPTER LEARNING OBJECTIVES
1. Describe the 10 basic elements of lean production. Lean production has truly changed the face of manufacturing and transformed the global economy. Originally known as just-in-time (JIT), it began at Toyota Motor Company as an effort to eliminate waste (particularly inventories). It has since evolved into a system for the continuous improvement of all aspects of manufacturing operations. Lean production is both a philosophy and a collection of management methods and techniques. The main advantage of the system is derived from the integration of the techniques into a focused, smooth-running management system. There are 10 basic elements to lean production:
1. Flexible resources
2. Cellular layouts
3. Pull system
4. Kanbans
5. Small lots
6. Quick setups
7. Uniform production levels
8. Quality at the source
9. Total productive maintenance
10. Supplier networks
2. Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production. Lean North American plants are typically larger, deliveries from suppliers are less frequent, more buffer inventory is held, and kanbans are very simple compared to lean plants in Japan. The slow pace of continuous improvement is hard to maintain for North American workers. Thus, kaizen blitzes, intense process improvement over a week’s time with immediate results, are easier and more energizing to conduct. Some benefits of lean production include reductions in manufacturing cycle time, reductions in inventory, reductions in labour costs, and reductions in space requirements. However, there are drawbacks. It can be difficult to maintain the discipline of lean production, and lean production may not be the best choice for high-volume repetitive items where mass production is more common. Also, lean production can present problems when unexpected changes in demand or supply occur.
3. Describe how lean systems can be applied in other situations, such as services, the supply chain, and environmental initiatives.
Other applications of lean production include:
Fast-food restaurants, where workers are added during peak times and reduced during slow times
Construction firms that coordinate the arrival of materials “just as needed” instead of stockpiling them on site
Companies where process mapping has streamlined operations and eliminated waste (especially in terms of paper flow and information processing)
Lens providers, cleaners, and car-repair services that turn around customer orders in an hour
Retailers who introduce dozens of new clothing lines each year in smaller quantities
TRUE-FALSE STATEMENTS
1. Kaizen is a Japanese term that means fool proofing to prevent defects.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
2. Mass production means doing more with fewer workers, less inventory, and less space.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
3. The individual generally credited with the development of lean production is an American.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
4. In lean production, waste is defined as anything that does not add value to the product.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
5. General purpose machines are an example of flexible resources.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
6. Producing items before they are needed is considered waste under the principles of lean production.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
7. Waiting for parts to arrive or for machines to finish production is considered a form of waste under the principles of mass production.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
8. The time required for a worker to complete one pass through the operations assigned to her is called the operator cycle time.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
9. Takt time is the pace at which production output is aligned with machine capacity.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
10. Manufacturing cells are comprised of similar machines to process a family of parts.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
11. Taiichi Ohno observed that customers in American supermarkets pull items through the system.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
12. Push systems rely on predetermined production schedules often generated by computerized systems.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
13. The concept of pull production is easy to implement because it is similar to traditional scheduling procedures.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
14. Kanbans were derived from the two-bin inventory system.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
15. A kanban square is a marked area designated for holding a set quantity of output.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
16. Kanbans are used to maintain the discipline required of a push production system.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
17. The number of kanbans needed to maintain control in a pull system can be calculated from demand and lead time information.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
18. Small-lot production reduces lead time but increases quality problems.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
19. Advantages of small-lot production include requiring less space and lower capital investment.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
20. The lower inventory levels associated with small-lot production make processes more dependent on each other.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
21. Setup time is not a component of the cumulative lead time for a manufactured product.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
22. The lower inventory levels resulting from small-lot production hides problems in the production process.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
23. Internal setup activities can be performed when a process is running.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
24. Reducing variability in production through more accurate demand forecasts is one way to maintain uniform production levels.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
25. A poka-yoke is any foolproof device that prevents defects or injury from occurring.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
26. The authority for a worker to stop the production line when quality problems are encountered is known as poka-yoke.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
27. Total productive maintenance combines preventive maintenance with kaizen.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
28. Lean concepts cannot be applied to services because services are intangible.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
29. Flexible resources are a basic element of lean production.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
30. The concept of cellular layouts was developed by a U.S. engineer in the 1920s.
Difficulty: Hard
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
31. The output of a manufacturing cell is changed by adding or removing workers.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
32. The pull system was developed by Ohno to coordinate production between processes.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
33. A push system prevents both overproduction and underproduction.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
34. In the dual kanban system, a withdrawal kanban authorizes the production of goods.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
35. One benefit of small-lot production is that workers show fewer tendencies to let poor quality pass.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
36. One component of lead time, setup time, is often the biggest bottle neck.
Difficulty: Hard
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
37. In lean production, a strong relationship exists between setup times and small lots.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
38. In a lean production system, kanban systems have been shown to handle large fluctuations in the production requirements on the final assembly line.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
39. Mixed-modelling sequencing is used at Toyota to reduce setup times.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
40. Poka-yoke is a Japanese term used to describe the removal of waste in a lean production system.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
41. To keep machines running, firms can use either breakdown maintenance or preventative maintenance.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
42. Firms that adopt lean production experience reductions in cycle time, inventory cost, and employee training costs.
Difficulty: Medium
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
AACSB: Reflective Thinking
43. Early adopters of lean production in North America were unsuccessful because they tried to implement lean by slashing inventories and forcing their suppliers to make more frequent deliveries.
Difficulty: Medium
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
MULTIPLE CHOICE QUESTIONS
44. All of the following factors pressure companies for quicker response and shorter cycle times except
a) demanding customers.
b) longer product life cycles.
c) globalization.
d) All the above are factors.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
45. ___ is generally credited with the development of lean production.
a) Frederick Taylor
b) W. Edwards Deming
c) Taiichi Ohno
d) none of the above
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
46. Which of the following is not a basic element of lean production?
a) flexible resources
b) pull system
c) repetitive production
d) small lot production
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
47. In lean production, waste is defined as
a) overproduction.
b) high levels of inventory.
c) unnecessary movement.
d) All the above are waste.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
48. The pace at which production should take place to match the rate of customer demand is known as
a) product flow time.
b) jidoka time.
c) kanban time.
d) takt time.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
49. In a pull production system, a card that corresponds to a standard quantity of production is known as a(n)
a) jidoka.
b) andon.
c) kanban.
d) kaizen.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
50. In a pull system reducing the number of kanbans
a) increases inventory making problems more visible.
b) reduces inventory making problems less visible.
c) reduces inventory making problems more visible.
d) increases inventory making problems less visible.
Difficulty: Hard
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
51. A workstation’s output is 200 bottles of wine per hour. It takes 45 minutes to receive a withdrawal kanban of corks from the previous workstation. The withdrawal kanban is attached to a container holding 30 corks. The process uses a safety factor of 20 percent. What is the number of withdrawal kanbans needed to support the bottling process?
a) 4
b) 5
c) 6
d) 3
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Analytic
52. A workstation’s output is 200 bottles of wine per hour. It takes 30 minutes to receive a withdrawal kanban of corks from the previous workstation. The withdrawal kanban is attached to a container holding 30 corks. The process uses a safety factor of 20 percent. What is the number of withdrawal kanbans needed to support the bottling process?
a) 10
b) 2
c) 8
d) 4
Difficulty: Hard
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Application
AACSB: Analytic
53. A workstation must produce 400 units an hour. It takes 24 minutes to receive the necessary material for production from the previous workstation. Output is moved between workstations in containers holding 44 units. If the process uses a safety factor of 10%, then the amount of safety stock on average would be
a) 16
b) 32
c) 8
d) 60
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Application
AACSB: Analytic
54. A workstation must produce 400 units an hour. It takes 24 minutes to receive the necessary material for production from the previous workstation. Output is moved between workstations in containers holding 44 units. If the process uses a safety factor of 10%, then the number of kanbans that should be circulating between this workstation and the previous workstation is
a) 2
b) 4
c) 6
d) 8
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Application
AACSB: Analytic
55. How many kanbans should circulate between two workstations if demand is 500 units per hour, lead time is 20 minutes, container sizes are 35, and the company uses a safety factor of 5%?
a) 4
b) 5
c) 12
d) 8
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Application
AACSB: Analytic
56. Which of the following statements concerning small-lot production is not true?
a) Small-lot production requires less space.
b) Small-lot production requires more capital investment.
c) Small-lot production simplifies transportation between workstations.
d) Small-lot production allows processes to be moved closer together.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
57. Lower inventory levels make processes
a) less dependent on each other while keeping bottlenecks hidden.
b) less dependent on each other while revealing bottlenecks more quickly.
c) more dependent on each other while revealing bottlenecks more quickly.
d) more dependent on each other while keeping bottlenecks hidden.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
58. Which of the following is not a typical component of lead time?
a) processing time
b) maintenance time
c) waiting time
d) setup time
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
59. Improved scheduling of materials, workers, and machines will most generally affect
a) processing time.
b) move time.
c) waiting time.
d) setup time.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
60. Which of the following is not a principle for reducing setup times?
a) converting external setup to internal setup
b) converting internal setup to external setup
c) separating internal setup from external setup
d) performing setup activities in parallel
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
61. ___ setups that can be performed in advance while the machine is running.
a) Internal
b) External
c) Parallel
d) Unnecessary
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
62. A ___ is a foolproof device that prevents defects from occurring.
a) kaizen
b) jidoka
c) muda
d) poka-yoke
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
63. The authority given to the worker to stop the production line if quality problems are encountered is known as
a) kaizen.
b) jidoka.
c) poka-yoke.
d) muda.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
64. The concept of allocating extra time to a schedule for planning, problem solving, and maintenance is known as
a) preventative scheduling.
b) preventive maintenance.
c) over capacity maintenance.
d) under capacity scheduling.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
65. The benefits of lean production include all of the following except reduced
a) inventory.
b) product variety.
c) pace requirements.
d) lead times.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
66. All of the following are benefits expected from implementing lean production except
a) better quality.
b) shorter lead times.
c) reduced capacity.
d) improved sales.
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
67. Lean production is difficult to implement when
a) demand is highly variable.
b) product variety is high.
c) there are many unique products.
d) all of the above are true.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
68. Combining the practice of preventive maintenance with the concepts of total quality is known as
a) total preventive quality.
b) total productive maintenance.
c) quality breakdown maintenance.
d) reliability assurance.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
69. Mixed-model sequencing
a) facilitates total productive maintenance.
b) achieves uniform production levels.
c) increases product lead times.
d) reduces worker productivity.
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking
70. Which of the following is not typically a component of lead time?
a) move time
b) breakdown time
c) wait time
d) setup time
Difficulty: Easy
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
71. A ___ kanban is used to order material in advance of production.
a) material
b) supplier
c) production
d) withdrawal
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
72. Procedures or mechanisms that make problems visible are examples of which of the following?
a) poke-yoke
b) kaizen
c) visual control
d) kanban
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
73. Which of the following is not a benefit of lean production?
a) greater flexibility
b) increased capacity
c) more customers
d) more product variety
Difficulty: Easy
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
AACSB: Reflective Thinking
74. Which of the following is not considered a benefit of lean production?
a) Reductions in manufacturing cycle time
b) reductions in inventory
c) reductions in labour costs
d) increases in automation
Difficulty: Medium
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
75. Which of the following is not considered a benefit of lean production?
a) less product variety
b) increased capacity
c) lower costs
d) greater flexibilty
Difficulty: Medium
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
Blooms: Comprehension
AACSB: Reflective Thinking
76. Which of the following is considered a benefit of lean production?
a) higher costs
b) strained relations with suppliers
c) better use of human resources
d) increased inventory
Difficulty: Medium
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
Blooms: Knowledge
AACSB: Reflective Thinking
77. Value stream mapping (VSM) is a tool for
a) reducing setup times.
b) improving quality at the source.
c) analyzing process flow.
d) designing manufacturing cells.
Difficulty: Medium
Learning Objective: Describe how lean systems can be applied in other situations, such as services, the supply chain, and environmental initiatives.
Section Reference: 16.3 Other Applications of Lean Systems
AACSB: Reflective Thinking
78. Analyzing process flow and eliminating waste is referred to as
a) just-in-time.
b) the Toyota Production System.
c) value stream mapping.
d) total productive maintenance.
Difficulty: Easy
Learning Objective: Describe how lean systems can be applied in other situations, such as services, the supply chain, and environmental initiatives.
Section Reference: 16.3 Other Applications of Lean Systems
AACSB: Reflective Thinking
79. Which of the following lean service systems involves smaller, more frequent orders and rapid replenishment of stock?
a) lean banking
b) lean health care
c) lean retailing
d) lean production
Difficulty: Medium
Learning Objective: Describe how lean systems can be applied in other situations, such as services, the supply chain, and environmental initiatives.
Section Reference: 16.3 Other Applications of Lean Systems
Blooms: Comprehension
AACSB: Reflective Thinking
SHORT-ANSWER ESSAY QUESTIONS
80. What role does the elimination of waste play in lean production?
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
AACSB: Reflective Thinking; Communication
81. What is a manufacturing cell and what is its purpose?
Difficulty: Hard
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Synthesis
AACSB: Reflective Thinking; Communication
82. How does the pull system differ from the push system?
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Evaluation
AACSB: Reflective Thinking; Communication
83. What is a kanban and how is it used in a pull system?
Difficulty: Medium
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Synthesis
AACSB: Reflective Thinking; Communication
84. What are the benefits of small-lot production?
Learning Objective: Describe the 10 basic elements of lean production.
Section Reference: 16.1 The Basic Elements of Lean Production
Blooms: Synthesis
AACSB: Reflective Thinking; Communication
85. Briefly discuss some of the drawbacks of lean production and provide examples of where lean production might not be most appropriate
Learning Objective: Contrast the application of lean concepts in North American-based facilities versus Japan-based facilities, and describe the benefits and drawbacks of lean production.
Section Reference: 16.2 Implementing Lean Production
Blooms: Evaluation
AACSB: Reflective Thinking; Communication
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