Which of the following is generally found in most lean environments?
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E) pull systems
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Which of the following is NOT a source of variability?
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C) Employees, machines, and suppliers produce units that conform to standards.
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Which of the following is specifically characterized by a focus on continuous improvement, respect for people, and standard work practices?
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B) Toyota Production System (TPS)
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Which of the following is specifically characterized by continuous and forced problem solving via a focus on throughput and reduced inventory?
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A) Just-in-time (JIT)
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Which of the following statements regarding a pull system is TRUE?
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D) Problems become more obvious.
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Manufacturing cycle time is best defined as the:
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E) time from raw materials receipt to finished product exit.
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Which of the following is specifically characterized by the elimination of waste through a focus on exactly what the customer wants?
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C) Lean operations
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Which of the following is NOT one of the Seven Wastes?
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C) assignment
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The 5Ss:
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E) All of these are true.
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The list of 5Ss, although it looks like a housekeeping directive, supports lean production by:
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A) identifying non-value items and removing them, in the "sort/segregate" category.
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________ is any deviation from the optimum process that delivers perfect product on time, every time.
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Variability
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A(n) ________ is a concept that results in material being produced only when requested and moved to where it is needed just as it is needed.
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pull system
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The ________ is the time between the arrival of raw materials and the shipping of finished products.
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manufacturing cycle time
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TPS stands for ________.
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Toyota Production System
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The 5S category ________ includes analysis to improve workflow and reduce wasted motion.
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simplify/straighten or simplify
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Handling material more than once is an example of the waste called ________.
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transportation
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Concerning relationships with suppliers, which of the following combinations is critical to the success of JIT?
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A) close relationships with trust
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Which one of the following is not a benefit of JIT implementation?
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B) variability increase
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If the goals of JIT partnerships are met, which of the following is a result?
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B) In-transit inventory falls as suppliers are located closer to facilities.
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Which one of the following is a characteristic of a JIT partnership?
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D) removal of incoming inspection
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Characteristics of just-in-time partnerships do NOT include:
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B) large lot sizes to save on setup costs and to gain quantity discounts.
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Which of the following is not a goal of JIT partnerships?
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D) inspect all incoming shipments to ensure zero defects
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Which of the following is NOT a goal of JIT partnerships?
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E) All of the above are goals of JIT partnerships.
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Which one of the following is a concern expressed by suppliers in JIT partnerships?
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C) having limited ability to respond to changes in product and quality
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How can a reduction of in-transit inventory be encouraged?
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A) supplier location near plants
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In JIT partnerships, suppliers have several concerns. Which of the following is NOT such a concern?
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E) customers' infrequent engineering changes
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Which of the following is NOT a concern of suppliers as they prepare to enter into JIT partnerships?
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E) All of the above represent JIT supplier concerns.
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Just-in-time systems make demands on layouts, including the need for:
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E) all of the above
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Which one of the following is NOT a layout tactic in a JIT environment?
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B) fixed equipment
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Who is credited with coining the phrase, "Inventory is evil"?
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D) Shigeo Shingo
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Which one of the following statements is TRUE regarding JIT inventory?
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B) It is the minimum inventory necessary to keep a perfect system running.
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A firm wants to develop a level material use schedule based on the following data. What should be the setup cost?
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A) $0.45
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A product has annual demand of 100,000 units. The plant manager wants production to follow a four-hour cycle. Based on the following data, what setup cost will enable the desired production cycle? d = 400 per day (250 days per year), p = 4000 units per day, H = $40 per unit per year, and Q = 200 (demand for four hours, half a day).
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B) $7.20
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Which of the following is TRUE regarding the steps to reducing setup times?
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E) All of the above are true.
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If a factory wants to cut its current lot size in half, by what proportion must setup cost change?
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A) Setup cost must be cut to one fourth its current value.
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Which one of the following statements is TRUE about the kanban system?
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E) The customer workstation signals to the supplier workstation when production is needed.
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Kanban is associated with all EXCEPT which of the following?
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D) increased material handling
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What does the Japanese word "kanban" mean?
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C) card
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Which one of the following scenarios represents the use of a kanban to reduce inventories?
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D) A "customer" work center signals to the "supplier" workstation that more parts are needed.
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The number of kanbans should be equal to which of the following?
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B) the ratio of (demand during lead time + safety stock) to container size
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Lead time for cakes is 2 days with daily demand of 10 cakes and a safety stock of ½ a day. Each container (kanban) holds 1 cake. What is the correct number of kanbans?
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E) 25
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The cook in a fast-food restaurant knows that 2 hamburger patties and an order of fries should be started for each car that is waiting in line. This is best an example of:
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B) kanban.
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Lead time for computers is 7 days with daily demand of 5 computers and a safety stock of 1 day. Each kanban holds 8 computers. What is the correct number of kanbans?
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C) 5
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Lead time for computers is 5 days with daily demand of 25 and safety stock of 5 computers. If management wants to use 10 kanbans how many computers should each one hold?
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E) 13
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A grocery store is attempting to implement a kanban system. Which of the following would not be an application of kanbans?
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D) The meat department stocking up on turkeys before Thanksgiving.
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Which of the following is FALSE regarding the links between JIT and quality?
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E) JIT increases the cost of obtaining good quality.
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JIT makes quality cheaper because:
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C) JIT prevents long runs of defects.
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Great Lakes Barge and Baggage Company makes, among other things, battery-operated bilge pumps. Which of the following activities is NOT part of JIT? They:
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B) produce in long production runs to reduce the impact of setup costs.
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A manufacturer took the following actions to reduce inventory. Which of these is generally not accepted as a JIT action?
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D) It picked the supplier that offered the lowest price based on quantity discounts.
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________ is the minimum inventory necessary to keep a perfect system running.
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Just-in-time inventory
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________ is the Japanese word for card that has come to mean "signal."
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Kanban
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When suppliers are encouraged to locate near manufacturing plants, the goal of the JIT partnership is to reduce ________ inventory.
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in-transit
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________ allows manufacturing work cells and offices to be easily rearranged.
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Layout flexibility
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________ involve scheduling products so that each day's production meets the demand for that day.
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Level schedules
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Which of the following is an illustration of employee empowerment?
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C) "No one knows the job better than those who do it."
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Which of the following is not characteristic of a TPS employee?
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B) strict job classifications
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Which of the following is NOT an attribute of lean operations?
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C) pushing responsibility to the highest level possible through centralized decision making
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Lean operations are known for their:
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E) All of the above are attributes of lean operations.
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Which of the following is characteristic of lean operations?
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D) low space requirements
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Excess bags of basic commodities such as flour and sugar that are stored in a restaurant's kitchen represent which of the following wastes?
answer
D) inventory
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