3020 Chapter 12: Lean Supply Chains

1. 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

2. The textbook The Toyota Production System identified which of the following types of waste to be eliminated? A. Excess quality B. Overproduction C. Underproduction D. Environmental E. Over-thinking

3. The textbook The Toyota Production System identified which of the following types of waste to be eliminated? A. Underproduction B. Excess quality C. Preventive maintenance D. Product defects E. Kaizen

4. The textbook The Toyota Production System identified which of the following types of waste to be eliminated? A. Excess quality B. Motion C. Excess capacity D. Underproduction E. Excess demand

5. 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

6. 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

7. 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

8. 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

9. 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 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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 nonlinearly 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

21. 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

22. 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

23. 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

24. 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. Kanban Card Systems D. Fully utilizing capacity E. Backflushing

25. 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