Test Questions & Answers Lean Systems Ch.16

File: ch16, Chapter 16: Lean Systems

True/False

1. _______ is a Japanese term that means fool proofing to prevent defects.
   1. Kaizen
   2. Andon
   3. Poka yoke
   4. Jidoka

Difficulty: Easy

Learning Objective: LO 1

1. Mass production means doing more with fewer workers, less inventory, and less space.

Difficulty: Easy

Learning Objective: LO 1

1. The individual generally credited with the development of lean production is
   1. Shigeo Shingo
   2. W. Edwards Deming
   3. Taiichi Ohno
   4. Genichi Taguchi
2. In lean production, waste is defined as anything that does not add value to the product.

Difficulty: Moderate

Learning Objective: LO 1

1. General purpose machines are an example of flexible resources in lean production.

Difficulty: Easy

Learning Objective: LO 1

1. Producing items before they are needed is considered what type of waste under the principles of lean production?
   1. waiting
   2. overproduction
   3. overprocessing
   4. inventory
2. Waiting for parts to arrive or for machines to finish production is considered a form of waste under the principles of mass production.

Difficulty: Moderate

Feedback: Basic Elements of Lean Production

Learning Objective: LO 1

1. The time required for a worker to complete one pass through the operations assigned to her is called the operator cycle time.

Difficulty: Moderate

Learning Objective: LO 1

1. Takt time is the pace at which production output is
   1. maximum.
   2. greater than customer demand.
   3. less than customer demand.
   4. equal to customer demand.
2. Manufacturing cells are comprised of groups of similar machines that process a family of parts.

Difficulty: Moderate

Learning Objective: LO 1

1. Taiichi Ohno observed that customers in American supermarkets pull items through the system based on what is needed to satisfy demand.

Difficulty: Moderate

Learning Objective: LO 1

1. Push systems rely on predetermined production schedules often generated by computerized systems.

Difficulty: Moderate

Learning Objective: LO 1

1. _________ systems rely on customer demand.
   1. Push
   2. Pull
   3. Demand management
   4. Demand planning
2. Kanbans were derived from the two-bin inventory system.

Difficulty: Moderate

Learning Objective: LO 1

1. A kanban square is a marked area designated for holding a set quantity of output.

Difficulty: Moderate

Learning Objective: LO 1

1. Kanbans are used to maintain the discipline required of a push production system.

Difficulty: Moderate

Learning Objective: LO 1

1. The number of kanbans needed to maintain control in a pull system can be calculated from demand and lead time information.

Difficulty: Moderate

Learning Objective: LO 1

1. Small-lot production reduces lead time but increases quality problems.

Difficulty: Moderate

Learning Objective: LO 1

1. Small-lot production requires
   1. less space and lower capital investment.
   2. more space and lower capital investment.
   3. less space and higher capital investment.
   4. more space and higher capital investment.
2. In small lot production, lower inventory levels do what?
   1. hide issues
   2. make process more dependent
   3. increase the number of kanbans
   4. increase storage costs.
3. Setup time is NOT a component of the cumulative lead time for a manufactured product.

Difficulty: Easy

Learning Objective: LO 1

1. The lower inventory levels resulting from small-lot production hide problems in the production process.

Difficulty: Moderate

Learning Objective: LO 1

1. Internal setup activities can be performed when a process is running.

Difficulty: Moderate

Learning Objective: LO 1

1. Reducing variability in production through more accurate demand forecasts is one way to create more uniform production levels.

Difficulty: Moderate

Learning Objective: LO 1

1. A poka-yoke is any foolproof device that prevents defects or injury from occurring.

Difficulty: Moderate

Learning Objective: LO 1

1. The authority for a worker to stop the production line when quality problems are encountered is known as
   1. total quality management.
   2. andon.
   3. poka-yoke
   4. jidoka.
2. Total productive maintenance combines preventive maintenance with kaizen.

Difficulty: Moderate

Learning Objective: LO 1

1. Lean concepts cannot be applied to services.

Difficulty: Easy

Learning Objective: LO 1

1. Flexible resources are one of the basic elements of lean production.

Difficulty: Easy

Learning Objective: LO 1

1. The concept of cellular layouts was developed by a U.S. engineer in the 1920s.

Difficulty: Hard

Learning Objective: LO 1

1. The output of a manufacturing cell is changed by adding or removing workers.

Difficulty: Easy

Learning Objective: LO 1

32. The pull system was developed by Ohno to coordinate production between processes.

Difficulty: Moderate

Learning Objective: LO 1

33. Unlike a pull system, a push system prevents both overproduction and underproduction.

Difficulty: Easy

Learning Objective: LO 1

34. In the dual kanban system, a withdrawal kanban authorizes the movement of goods.

Difficulty: Moderate

Learning Objective: LO 1

35. One benefit of small lot production is that workers demonstrate fewer tendencies to let poor quality pass.

Difficulty: Easy

Learning Objective: LO 1

36. In lean production, a strong relationship exists between setup times and lot size.

Difficulty: Moderate

Learning Objective: LO 1

37. In a lean production system, kanban systems have been shown to handle large fluctuations in production requirements on the final assembly line with no problem.

Difficulty: Easy

Learning Objective: LO 1

38. Mixed-modeling sequencing is used at Toyota to create uniform production levels.

Difficulty: Easy

Learning Objective: LO 1

39. How many times does the question “Why?” need to be asked to typically find the root cause of a problem?

1. 3
2. 4
3. 5
4. 6

40. What is a system that performs period inspection and maintenance to keep a machine in operation?

1. breakdown maintenance
2. repair maintenance
3. preventive maintenance
4. predictive maintenance

41. Firms that adopt lean production experience reductions in employee training costs.

Difficulty: Moderate

Learning Objective: LO 2

42. Early adopters of lean production in the U.S. were unsuccessful because they tried to implement lean by slashing inventories by forcing their suppliers to make more frequent deliveries.

Difficulty: Moderate

Learning Objective: LO 2

Multiple Choice

43. All of the following factors pressure companies for quicker response and shorter cycle times except

1. demanding customers.
2. longer product life cycles.
3. globalization.
4. All of the answer choices are correct.

Difficulty: Easy

Learning Objective: LO 1

1. ___________ is generally credited with the development of lean production.
2. Frederick Taylor
3. W. Edwards Deming
4. Taiichi Ohno
5. None of the answer choices is correct.

Difficulty: Easy

Learning Objective: LO 1

1. Which of the following is not a basic element of lean production?
2. flexible resources
3. pull system
4. repetitive production
5. small lot production

Difficulty: Moderate

Learning Objective: LO 1

1. In lean production, waste is defined as
2. overproduction.
3. high levels of inventory.
4. unnecessary movement.
5. All of the answer choices are correct.

Difficulty: Easy

Learning Objective: LO 1

1. The pace at which production should take place to match the rate of customer demand is known as
2. product flow time.
3. jidoka time.
4. kanban time.
5. takt time.

Difficulty: Moderate

Learning Objective: LO 1

48. In a pull production system, a card that corresponds to a standard quantity of production is known as a(n)

1. jidoka.
2. andon.
3. kanban.
4. kaizen.

Difficulty: Moderate

Learning Objective: LO 1

1. In a pull system reducing the number of kanbans
2. increases inventory making problems more visible.
3. reduces inventory making problems less visible.
4. reduces inventory making problems more visible.
5. increases inventory making problems less visible.

Difficulty: Hard

Learning Objective: LO 1

50. 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?

1. 4
2. 5
3. 6
4. 3

Difficulty: Moderate

Solution: N = (200 × 0.75 + 0.20 × 200 × 0.75)/30 = 6

Learning Objective: LO 1

1. 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?
2. 10
3. 2
4. 8
5. 4

Difficulty: Hard

Solution: N = (200 × 0.50 + 0.20 × 200 × 0.5)/30 = 4

Learning Objective: LO 1

1. 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
2. 16
3. 32
4. 8
5. 60

Difficulty: Moderate

Solution: S=0.10 × 400 × 0.40 = 16

Learning Objective: LO 1

1. 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
2. 2.
3. 4.
4. 6.
5. 8.

Difficulty: Moderate

Solution: N = (400 × 0.40 + 0.10 × 400 × 0.40)/44 = 4

Learning Objective: LO 1

1. 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%?
2. 4
3. 5
4. 12
5. 8

Difficulty: Moderate

Solution: N = (500 × 0.33 + 0.05 × 500 × .33)/35 = 5

Learning Objective: LO 1

1. 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: Moderate

Learning Objective: LO 1

1. Lower inventory levels make processes
2. less dependent on each other while keeping bottlenecks hidden.
3. less dependent on each other while revealing bottlenecks more quickly.
4. more dependent on each other while revealing bottlenecks more quickly.
5. more dependent on each other while keeping bottlenecks hidden.

Difficulty: Moderate

Learning Objective: LO 1

1. Which of the following is not a typical component of lead time?
2. processing time
3. maintenance time
4. waiting time
5. setup time

Difficulty: Moderate

Learning Objective: LO 1

1. Improved scheduling of materials, workers, and machines will most generally affect
2. processing time.
3. move time.
4. waiting time.
5. setup time.

Difficulty: Easy

Learning Objective: LO 1

1. Which of the following is not a principle for reducing setup times?
2. converting external setup to internal setup
3. converting internal setup to external setup
4. separating internal setup from external setup
5. performing setup activities in parallel

Difficulty: Moderate

Learning Objective: LO 1

1. ______________ setups can be performed in advance while the machine is running.
2. Internal
3. External
4. Parallel
5. Unnecessary

Difficulty: Easy

Learning Objective: LO 1

1. A ___________ is a foolproof device that prevents defects from occurring.
2. kaizen
3. jidoka
4. muda
5. poka-yoke

Difficulty: Moderate

Learning Objective: LO 1

1. The authority given to the worker to stop the production line if quality problems are encountered is known as
2. kaizen.
3. jidoka.
4. poka-yoke
5. muda.

Difficulty: Moderate

Learning Objective: LO 1

1. The concept of allocating extra time to a schedule for planning, problem solving, and maintenance is known as
2. preventative scheduling.
3. preventive maintenance.
4. over capacity maintenance.
5. under capacity scheduling.

Difficulty: Moderate

Learning Objective: LO 1

1. The benefits of lean production include all of the following except reduced
2. inventory.
3. product variety.
4. costs.
5. lead times.

Difficulty: Easy

1. All of the following are benefits expected from implementing lean production except
2. better quality.
3. shorter lead times.
4. reduced capacity.
5. improved sales.

Difficulty: Moderate

Learning Objective: LO 1

1. Lean production is difficult to implement when
2. demand is highly variable.
3. product variety is high.
4. there are many unique products.
5. All of these answer choices are correct.

Difficulty: Easy

Learning Objective: LO 1

1. Combining the practice of preventive maintenance with the concepts of total quality is known as
2. total preventive quality.
3. total productive maintenance.
4. quality breakdown maintenance.
5. reliability assurance.

Difficulty: Easy

Learning Objective: LO 1

1. Mixed-model sequencing
2. facilitates total productive maintenance.
3. supports uniform production levels.
4. increases product lead times.
5. reduces worker productivity.

Difficulty: Easy

Learning Objective: LO 1

1. Which of the following is not typically a component of lead time?
   1. move time.
   2. breakdown time.
   3. wait time.
   4. setup time.

Difficulty: Easy

Learning Objective: LO 1

1. A ____________ kanban is used to order material in advance of production.
   1. material
   2. supplier
   3. production
   4. withdrawal

Difficulty: Moderate

Learning Objective: LO 1

1. Which of the following is not a benefit of lean production?
   1. greater flexibility
   2. increased capacity
   3. more customers
   4. more product variety

Difficulty: Easy

Learning Objective: LO 1

1. Successful companies use lean to
   a. finely tune an operating system.

b. overhaul an operating system.

c. replace an operating system.

d. None of these answer choices is correct.

Difficulty: Moderate

Learning Objective: LO 2

1. Which of the following are characteristic of lean applications U.S. soil?
   a. plants are larger

b. deliveries from suppliers are less frequent

c. Kanbans are kept very simple.

d. All of these answer choices are correct.

Difficulty; Easy

Learning Objective: LO 2

1. American workers implementing lean prefer
   1. the slow pace of continuous improvement.
   2. the fast pace of kaizen blitzes.
   3. to never participate.
   4. to disrupt the process.

Difficulty: Moderate

Learning Objective: LO 2

1. Lean can have serious deficiencies when applied to companies that have
   a. high variability in demand.

b. large variety of low-volume products.

c. custom engineered products.

d. All of these answer choices are correct.

Difficulty: Moderate

Learning Objective: LO 2

1. Lean and Six Sigma are
   a. natural partners for process improvement.
   b. natural partners for supply chain management.
   c. poor partners for process improvement.
   d. poor partners for supply chain improvement.

Difficulty: Easy

Learning Objective: LO 3

1. Value stream mapping (VSM) is a tool for
   1. reducing setup times.
   2. improving quality at the source.
   3. analyzing process flow.
   4. designing manufacturing cells.

Difficulty: Moderate

Learning Objective: LO 4

1. Analyzing process flow and eliminating waste is referred to as
   1. just-in-time.
   2. the Toyota Production System.
   3. value stream mapping
   4. total productive maintenance.

Difficulty: Easy

Learning Objective: LO 4

1. Which of the following is not a recommendation by the EPA concerning integrating lean and environmental initiatives?
   a. Use lean process tools to identify areas of environmental waste.
   b. Incorporate environmental, safety, and health data into value mapping.
   c. Add environmental waste to the seven wastes of lean.
   d. Use lean concepts to eliminate all environment waste.

Difficulty: Moderate

Learning Objective: LO 5

1. The most prevalent applications of lean include all the following except
   a. retailing.

b. health care.
c. food services.

d. banking.

Difficulty: Moderate

Learning Objective: LO 6

1. Leaning a supply chain ____________ flow through a series of suppliers.
   a. pushes a smooth
   b. pulls a smooth
   c. pushes an intermittent
   d. pulls an intermittent

Difficulty: Moderate

Learning Objective: LO 6

Short Answer

82. What role does the elimination of waste play in lean production?

Difficulty: Moderate

Learning Objective: LO 1

83. What is a manufacturing cell and what is its purpose?

Difficulty: Hard

Learning Objective: LO 1

84. How does the pull system differ from the push system?

Difficulty: Moderate

Learning Objective: LO 1

85. What is a kanban and how is it used in a pull system?

Difficulty: moderate

Learning Objective: LO 1

86. What are the benefits of small-lot production?

Difficulty: moderate

Learning Objective: LO 1

87. All of the following are elements of lean production, except __________.

a) supplier networks

b) kanbans

c) cellular layouts

d) varied production levels

88. Which of the following choices is not true about lean production?

a) It means doing more with less—less inventory, fewer workers, less space.

b) It was coined to describe the Toyota Production System, widely recognized as the most efficient manufacturing system in the world.

c) The terms “just-in-time” (JIT) and “lean production” are currently used interchangeably.

d) It emphasizes elimination of waste but doesn’t focus on continuous improvement of operations.

89. The concept of flexible resources __________.

a) includes multifunctional workers

b) is usually not considered a core element of lean manufacturing

c) was one of the last elements to be adopted by lean manufacturing

d) is equivalent to the concept of kanbans

90. Which of the following choices is not true about kanbans?

a) Kanbans maintain the discipline of pull production by authorizing the production and movement of materials.

b) There are many different types and variations of kanbans.

c) Kanbans make the schedule of production.

91. What is the difference between the kanban system and the reorder point system?

a) The reorder point system attempts to create a permanent ordering policy, whereas the kanban system encourages the continual reduction of inventory.

b) Both concepts are equivalent, and there are no important differences.

c) The reorder point system applies to the suppliers, whereas the kanban system applies to the production process.

d) The reorder point system evolved into the kanban system with the widespread adoption of lean manufacturing.

92. Which of the following choices is not true about small-lot production?

a) Small-lots production requires less space and capital investment than systems that incur large inventories.

b) It allows processes to be physically moved closer together.

c) One of its disadvantages is that it maker errors harder to detect.

d) It is difficult to coordinate in a push system.

93. One of the principles on which the SMED (single-minute exchange of dies) system is based is that it __________.

a) converts external setups to internal setups

b) streamlines all aspects of setup

c) outsources external setups

d) performs setup activities in series with maximum efficiency

94. Total productive maintenance __________.

a) combines the practice of preventive maintenance with the concept of total quality

b) requires management to take a broader, strategic view of maintenance

c) includes training and retraining workers to operate and maintain machines properly

d) All of the above choices are correct.

95. Supplier networks __________.

a) is about the interface between the company and its suppliers, but suppliers are not necessarily lean can and do work with lean customers

b) usually don’t include supplier certification

c) require imperatively that the source of supply be located close to the customer

d) require uniform loads and medium-frequency deliveries

96. Which of the following is not a benefit of lean production?

a) Lower costs

b) Reduced inventory

c) Reduced need for employee training

d) Increased capacity