BUS 370 Chapter 14

Which of the following is not something commonly found in lean systems? (I) Waste reduction (II) Output match to a detailed forecast (III) Visual controls (IV) Quick changeovers (V) Long production runs

Which of the following is not a principle regarding the way lean systems function? (I) Identifying customer values (II) Focusing on processes that create value (III) Elimination of waste to create flow (IV) Increasing forecast accuracy (V) Producing only according to customer demand (VI) Optimizing on setup costs with long production runs (VII) Striving for perfection

In the Toyota Production System, waste and inefficiency are referred to as __________, and long-term reduction of this is referred to as __________. A. jidoka; heijunka B. muda; kanban C. kaizen; heijunka D. muda; kaizen E. muda; jidoka

Although lean systems tend to produce standardized product lines, to provide production variety without accompanying waste, lean producers often use __________ in __________. A. standardized parts; modular designs B. jidoka parts; kaizen designs C. modular parts; flexible designs D. capable parts; automated designs

Lean systems often rely on a method of overhead allocation known as: A. direct-labor allocation. B. capital-charge allocation. C. mixed-model accounting. D. activity-based costing. E. indirect-labor allocation.

A lean-systems method of asking questions about a process is the __________ approach. A. jidoka B. 3 kanban C. heijunka D. 2 kaizen E. 5W2H

Although transitioning to a lean system can be a powerful means of improving performance, it is generally thought that using __________ along with lean can lead to even better results. A. kaizen B. ERP C. six sigma D. JIT E. jidoka

For a company with a product mix of 40 percent of product A and 30 percent each of products B and C, which of the following mixed-model sequences best reflects the lean philosophy? A. AABBCCAABC B. ABCABCABCA C. AAAABBBCCC D. BCABCABCAB E. BBBAACCCAA

The lean philosophy suggests that workers are: A. assets. B. liabilities. C. interchangeable. D. replaceable. E. to be phased out.

The ultimate goal of lean operations is to have: A. no in-process inventories. B. cross-trained workers capable of handling every process. C. a smooth, rapid flow of materials through the system. D. no setup times. E. all of the choices.

Which one of the following is not one of the building blocks that is the foundation of the lean philosophy? A. product design B. process design C. personnel/organizational elements D. manufacturing planning and control E. kanban

Building up an inventory of standard parts or modules instead of immediately producing the finished end items is the essence of: A. delayed differentiation. B. kanban. C. autonomation. D. andon. E. matrix management.

Which of the following would you not expect to see in a lean environment? A. a flexible system B. minimum inventory C. little waste D. reduced setup times E. a significant number of daily schedule changes

The comprehensive approach used in lean systems to deal with quality includes: A. designing quality into products and processes. B. insisting vendors provide high-quality materials. C. making workers responsible for producing high quality. D. designing in quality, insisting on quality materials, and making workers responsible for quality. E. 100 percent inspection of raw materials, work-in-process, and finished goods.

Which of the following is not a benefit of small lot sizes in lean systems? A. In-process inventory is considerably less. B. Each product is produced less frequently. C. Carrying costs are reduced. D. There is less clutter in the workplace. E. Inspection and rework costs are less. Each product is produced more frequently with small lot sizes.

In the lean philosophy, the ideal lot size is: A. the economic order quantity. B. the economic run size. C. one unit. D. the capacity of the standard container. E. N = (DT(1 + X))/C.

Which of the following does not contribute to reduced setup time and cost? A. standardized setup tools B. standardized setup equipment C. custom setup procedures for each product D. use of multipurpose equipment or attachments E. use of group technology

A conveyance __________ signals parts movement. A. request B. routing C. bar code D. kanban E. kazian

The term that refers to the automatic detection of defects is: A. kaizen. B. kanban. C. autonomation. D. automation. E. 100 percent inspection.

A basic requirement for operating with the low inventories present in lean systems is: A. Inventory space must be increased. B. Inventory investment must be increased. C. Major problems must be identified. D. Major problems must have been solved. E. Inventories must be reduced rapidly.

Which of the following is not characteristic of preventive maintenance in lean systems? A. maintaining equipment in good operating condition B. replacing parts when they are worn but before they fail C. workers maintaining their own equipment D. eliminating supplies of spare parts to reduce capital investment E. perceiving breakdowns as an opportunity for improvement

The Five S's do not include: A. Sort. B. Straighten. C. Sanitize. D. Sweep. E. Standardize.

The kaizen philosophy applies to: A. employee development. B. safety stock. C. waste. D. supply chain management. E. MRP III.

A production kanban card is used to signal that: A. work is needed at the work center. B. work is ready to be moved to the next station. C. a problem exists. D. a machine has broken down and needs immediate attention. E. a machine is ready for preventive maintenance.

With regard to suppliers, lean systems typically require: A. delivery of large lots at regular intervals. B. buyer inspection of goods and materials. C. multiple sources from which to purchase. D. long-term relationships and commitments. E. the lowest price possible.

Which of the following is characteristic of the lean philosophy? A. Inventories are an asset. B. Lot sizes are optimized by formula. C. Vendors are coworkers, essentially other departments of our organization. D. Queues are a necessary investment. E. All of the choices. Long-term relationships help ensure that suppliers become partners in the lean firm's waste-reduction efforts.

The activity controlled in the same way by both kanban and MRP is the determination of: A. rates of output. B. products to be built. C. materials required. D. capacity required. E. feedback information.

Process design that supports lean does not include: A. production flexibility. B. duplicate facilities. C. setup time reduction. D. minimal inventory storage. E. small lot sizes. Facilities duplication would be inherently wasteful.

Which of the following questions is not answered by value stream mapping? A. Where does waste occur? B. Which processes or subprocesses exhibit the most variability? C. Where are the best opportunities to extract more value from customers? D. Where are process bottlenecks? E. Where do errors occur?

A successful conversion to a lean system requires that the conversion: A. be done as quickly as possible. B. begin at the start of the process and work forward. C. convert vendors to lean as one of the last steps. D. reduce setup times as one of the last steps. E. all of the choices.

A potential obstacle to conversion to a lean system is: A. lack of management commitment. B. lack of worker cooperation. C. supplier resistance. D. all of the choices. E. insufficient space to store the increased inventories

A system of lights used at each workstation to signal problems or slowdowns is: A. a command and control center. B. automation. C. andon. D. a pull system. E. kanban.

Which of the following contributes to the competitive advantage enjoyed by firms using lean production? A. backup employees to cover for absenteeism B. one hundred percent inspection to remove defects C. dedicated equipment to reduce unit costs D. safety stocks to prevent stockouts E. greater flexibility to cope with change

An operations strategy reflecting the lean philosophy of production should recognize that lean: A. is most suited for nonrepetitive manufacturing. B. cannot be implemented sequentially. C. requires a wholesale commitment from the outset. D. may provide a competitive advantage. E. all of the choices.

With regard to suppliers, lean systems typically involve: A. delivery of large lots on short notice B. the highest quality at the lowest price C. long-term relationships D. multiple suppliers to assure continuous availability E. dedicated staging areas for material

A common objective of both MRP and the lean philosophy is to: A. smooth production. B. minimize inventory. C. obtain high quality. D. reduce overhead. E. eliminate inventory.

The ultimate objective in a lean system is: A. low to moderate levels of inventory. B. high quality, zero defects. C. minimal waste (less than 6 percent). D. balanced and rapid flow. E. all of these.

When lean is used in the context of services, which of the following is most often the focus? A. the labor content of the service B. the time needed to perform a service C. the inventory tied up in the service D. the equipment used in the service E. suppliers of inputs to the service

Which of the following would not contribute to the leaning of services? A. Improve the reliability of vendors. B. Increase the flexibility of the service system. C. Have service workers handle multiple tasks. D. Standardize the service output. E. Improve the service process.

Having a vendor be responsible for managing the restocking of inventory is what is meant by the term: A. JIT II. B. MRP II. C. SCM I. D. EOQ III. E. POQ II.