Ch. 12

Lean production is an integrated set of activities designed to achieve high-volume production using minimal inventories of raw materials, work in process, and finished goods.

True

Henry Ford used JIT concepts as he streamlined his moving assembly lines to make automobiles in the early 1900’s.

True

Lean production requires a "push & pull" system of inventory replenishment.

False

Lean production replaced JIT in the 1990s because JIT did not address the problem of reducing waste.

False

Lean production is a management philosophy and a pull system throughout the plant.

True

Lean production makes implementing green strategies in manufacturing processes more difficult.

False

Group technology is a philosophy wherein similar parts are grouped together and the processes required to make the parts are arranged as a work cell.

True

Group technology cells help to eliminate movement and queue (waiting) time between operations.

true

Group technology includes the set of psychological tests and training exercises given to group workers to insure a high level of teamwork.

False

In the textbook the expression "quality at the source" means that we need to purchase the best quality a supplier or vendor can provide.

FALSE Quality at the source means do it right the first time and, when something goes wrong, stop the process or assembly line immediately.

"Quality at the source" requires factory workers to become their own inspectors.

True

JIT production means that we produce the product before it is required so the customer does not wait for the product.

FALSE Just-in-time means producing what is needed when needed and no more.

The goal of JIT production is to drive all inventory queues lower.

FALSE The goal (of JIT) is to drive all inventory queues to zero, thus minimizing inventory investment and shortening lead times.

JIT is typically applied to non-repetitive manufacturing.

FALSE JIT is typically applied to repetitive manufacturing, which is when the same or similar items are made one after another.

JIT manufacturing forces a firm to work with a lower water level despite safety hazards

FALSE Exhibit 12.6 presents water levels as an allegory for inventory levels. Lower water levels expose potential problems (rocks). Using JIT reduces inventory to a minimum level. Thus, "JIT manufacturing exposes problems otherwise hidden by excess inventories and staff." None of this has to do with actual water or safety hazards.

A principle of value stream mapping is to concentrate on speeding up value-added operations.

FALSE Value stream mapping (VSM) is a special type of flowcharting tool that is valuable for the development of lean processes. The technique is used to visualize product flows through various processing steps.

One of the aims of value stream mapping to eliminate waste in a process.

True

Uniform plant loading is where you schedule production with different amounts of the same product each day of the week to permit variation to meet changing demand requirements.

FALSE (Uniform plant loading is) building the same mix of products every day in small quantities. Thus, a total mix is always available to respond to variations in demand.

Uniform plant loading is a process of smoothing the production activity flow to dampen the reaction waves that normally occur in response to schedule variations.

True

Value stream mapping is used to visualize product flows through various processing steps.

True

A Kanban control system uses a signaling device to regulate JIT flows.

True

Kanban means "symbol" or "box" in Japanese.

False

Using the formula in the textbook the only parameters we need to determine the number of Kanban card sets is the average number of units demanded over some time period, the container size, and the safety stock.

False

"Kanban Squares" is an educational game played in Kanban training sessions.

False

Respect for people is a key to Toyota’s improvement ideas in manufacturing.

True

In Japanese manufacturing automation and robotics are used extensively to perform dull or routine jobs so employees are free to focus on important improvement tasks.

True

Subcontractor networks are not very important in Japanese manufacturing.

FALSE Toyota relies heavily on subcontractor networks.

Company unions in Japan exist to foster a cooperative relationship with management.

True

Firms in Japan tend to have short-term relationships with their suppliers and customers.

False

One of the many lean techniques that have been successfully applied in service firms is the upgrading of quality.

True

One of the many lean techniques that have been successfully applied in service firms is the upgrading of housekeeping.

True

One of the many lean techniques that have been successfully applied in service firms is leveling facility load.

True

One of the many lean techniques that have been successfully applied in service firms is the eliminating of unnecessary activities.

True

One of the few lean techniques that does not work well in service firms is demand-pull scheduling.

False

The term "freeze window" refers to the practice of building quality into the process and not identifying quality by inspection.

False

Preventive maintenance is emphasized in lean production to ensure that flows are not interrupted by downtime or malfunctioning equipment.

True

Value stream mapping is used to identify all of the value-adding as well as non-value-adding processes that materials are subjected to within a plant.

True

Value stream mapping involves materials, not information.

False

A kaizen burst is a symbol on a value stream map.

True

A kaizen burst is an overfilled kanban container.

False

Automation is a key to lean procurement.

True

Applying lean concepts in manufacturing balances increases in cost with quality improvement

False Applying lean concepts in manufacturing typically presents the greatest opportunities for cost reduction and quality improvement.

Applying lean concepts to logistics is difficult unless either the manufacturer or the customer owns the logistics activities.

FALSE Lean concepts can be applied to the functions associated with the movement of material through the system. Some of the key areas include optimized mode selection and pooling orders; combined multi-stop truckloads; optimized routing; cross docking; import/export transportation processes; and backhaul minimization.

Which of the following are related to lean production?

A. A philosophy of waste elimination

B. Lean consumption

C. Never running out of inventory

D. The Wahei-Subaru method

E. Full use of capacity

A philosophy of waste elimination

In the textbook Toyota’s Fujio Cho identified which of the following types of waste to be eliminated?

A. Excess quality

B. Overproduction

C. Underproduction

D. Environmental

E. Over-thinking

Overproduction Fujio Cho identifies seven prominent types of waste to be eliminated from the supply chain: (1) waste from overproduction, (2) waste of waiting time, (3) transportation waste, (4) inventory waste, (5) processing waste, (6) waste of motion, and (7) waste from product defects.

In the textbook Toyota’s Fujio Cho identified which of the following types of waste to be eliminated?

A. Underproduction

B. Excess quality

C. Preventive maintenance

D. Product defects

E. Kaizen

Product defects

In the textbook Toyota’s Fujio Cho identified which of the following types of waste to be eliminated?

A. Excess quality

B. Motion

C. Excess capacity

D. Underproduction

E. Excess demand

Motion

Which of the following address elimination of waste under lean production?

A. Info-matic warehouse networks

B. Outsourced housekeeping

C. Quality at the source

D. Backflush

E. Bottom-round management

Quality at the source Quality at the source means do it right the first time and, when something goes wrong, stop the process or assembly line immediately.

Which of the following are elements that address elimination of waste under lean production?

A. Production ahead of demand

B. Group plant loading technology

C. Kanban production control system

D. Minimized run times

E. Full capacity utilization

Kanban production control system

Group technology (GT) is credited with which of the following benefits?

A. Reducing waiting time between process operations

B. Improving inventory discipline

C. Reducing required workforce skills

D. Improved labor relations

E. Improved small group functioning

Reducing waiting time between process operations

Which of the following statements holds true for Kanban production control systems?

A. The authority to produce or supply additional parts comes from upstream operations

B. In a paperless control system, containers can be used instead of cards

C. The cards or containers make up the Kanban push system

D. They require substantial quantitative analysis prior to implementation

E. They have not been successful outside of Japan and the United States

In a paperless control system, containers can be used instead of cards

n setting up a Kanban control system you need to determine the number of Kanban card sets needed. If the expected demand during lead time is 25 per hour, the safety stock is 20% of the demand during lead time, the container size is 5, and the lead time to replenish an order is 5 hours, what is the number of Kanban card sets needed?

A. 5

B. 20

C. 27

D. 30

E. 34

30

In setting up a Kanban control system you need to determine the number of Kanban card sets needed. If the expected demand during lead time is 50 per hour, the safety stock is 20% of the demand during lead time, the container size is 4. If the lead time to replenish an order is 8 hours, what number of Kanban card sets is needed?

A. 60

B. 80

C. 90

D. 120

E. 150

120

You have been called in as a consultant to set up a Kanban control system. The first thing to do is to determine the number of Kanban card sets needed. Your research shows that the expected demand during lead time for a particular component is 150 per hour. You estimate the safety stock should be set at 25% of the demand during lead time. The tote trays used as containers can hold 8 units of stock and the lead time it takes to replenish an order is 2 hours. Which of the following is the number of Kanban card sets necessary to support this situation?

A. 42

B. 47

C. 68

D. 89

E. 94

47

You have been called in as a consultant to set up a Kanban control system. The first thing you do is to determine the number of Kanban card sets needed. Your research shows that the expected demand during lead time for a particular component is 1,200 per hour. You estimate the safety stock should be set at 5% of the demand during lead time. The tote trays used as containers can hold 2 units of stock and the lead time to replenish an order is 10 hours. Which of the following is the number of Kanban card sets necessary to support this situation?

A. 5,000

B. 5,500

C. 6,300

D. 6,500

E. 7,000

6,300

In designing a lean production facility layout a designer should do which of the following?

A. Design for work flow balance

B. Locate flexible workstations off line

C. Link operations through a push system

D. Balance capacity using job shop analysis

E. Always keep operations on a single floor of the factory

Design for work flow balance

When implementing a lean production system a stabilized schedule is achieved using which of the following?

A. Level scheduling

B. Demand pull

C. Freeze window

D. Reduced lot sizes

E. Bottom-round management

Level scheduling

To implement lean production schedules a firm would do which of the following?

A. Have excess capacity

B. Force demand

C. Hire a consultant

D. Bottom-up management

E. Implement kanban groups

Have excess capacity

In implementing a lean production system you should work with suppliers to do which of the following?

A. Open facilities near your factory

B. Focus workstation capacities

C. Backflush

D. Provide quality at the source

E. Reduce lead times

Reduce lead times

In implementing a lean production system you should work with suppliers to do which of the following?

A. Calculate lead times

B. Quality circles

C. Freeze windows

D. Make frequent deliveries

E. Achieve bottom-round management

Make frequent deliveries

To implement a flow process in developing a lean system a firm might do which of the following?

A. Improve capacity utilization

B. Build product in anticipation of demand

C. Reduce setup/changeover time

D. Eliminate some fixed costs

E. Implement groupware

Reduce setup/changeover time

To develop a lean manufacturing system a firm might do which of the following?

A. Eliminate anything that does not add value for the customer

B. Standardize product configurations

C. Process design with product design

D. Adopt a kaizen philosophy

E. Implement top-down management controls

Eliminate anything that does not add value for the customer

Imagine comparing a manufacturing operation using regular lot-sizing and the same operation with a Kanban/lean production approach. What would be your expectations of the difference between the total cost (i.e., inventory holding costs + setup/ordering costs) of each?

A. Inventory holding cost will increase non-linearly with inventory

B. Total costs will be lower for the regular lot-size operation

C. Total costs will be lower for the Kanban/lean production operation

D. The order quantity will be larger for the Kanban/lean production approach

E. As long as the total quantity is the same, total costs will be the same

Total costs will be lower for the Kanban/lean production operation

In a lean production system we expect to see which of the following?

A. No extra inventory

B. Extra inventory of critical parts held "just-in-case"

C. More parts and fewer standardized product configurations

D. Managers being held responsible for quality of the work turned out

E. Closer management-labor relationships

no extra inventory

Which of the following is a lean production technique that is not reported in the textbook to have been successfully applied in service firms?

A. Organize problem-solving groups

B. Upgrade housekeeping

C. Upgrade quality

D. Freeze windows

E. Eliminate unnecessary activities

Freeze Windows

An activity where the parts that go into each unit of a product are periodically removed from inventory and accounted for based on the number of units produced. is called which of the following?

A. Frozen window

B. Backflush

C. Level schedule

D. Group Technology

E. Kanban

Backflush

Which of the following is a lean production technique that has been successfully applied in service firms?

A. Decision trees

B. Leveling the facility load

C. Linear programming

D. Fully utilizing capacity

E. Backflushing

Backflushing

Which of the following is not listed in the textbook as a component of a lean supply chain?

A. Lean customers

B. Lean Management

C. Lean logistics

D. Lean warehousing

E. Lean procurement

Lean Management

In setting up a kanban control system you need to determine the number of kanban card sets needed. If the expected demand during lead time is 24 per hour, safety stock is 10% of the demand during lead time, the container size is 5. If the lead time to replenish an order is 5 hours, what number of kanban card sets is needed?

27

In setting up a kanban control system and you need to determine the number of kanban card sets needed. If the expected demand during lead time is 50 per hour, the safety stock is 20% of the demand during lead time, the container size is 4. If the lead time to replenish an order is 2 hours, what number of kanban card sets is needed?

30

Name Fujio Cho’s seven prominent types of waste to be eliminated

(1.) Waste from overproduction; (2.) Waste of waiting time; (3.) Transportation waste; (4.) Inventory waste; (5.) Processing waste; (6.) Waste of motion; (7.) Waste from product defects