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Chapter 07 - Lean Thinking and Lean Systems

Chapter 07 Lean Thinking and Lean Systems Multiple Choice Questions

1. Under lean, the ROI is increased by: A. An increase in revenues B. Cost reductions C. Fewer investments D. Both a and b E. Both b and c F. a, b, and c

2. Which of the following is not an element of lean?

A. Small-lot production B. Modularized master schedule C. Multifunction workers D. Kanban pull system E. Perfect or nearly perfect quality

3. A kanban card is used to signal that: A. The next work center is stopped B. A materials handler has run out of parts C. A machine has broken down D. Parts are needed by the subsequent work center E. A machine is ready for preventive maintenance

4. Lean emphasizes all of the following except: A. Setup time reductions B. Cross training of workers C. Lot size reduction D. Elimination of waste E. Supplier development F. Increased utilization of machines

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Chapter 07 - Lean Thinking and Lean Systems

5. For production control, lean pull systems are best suited for: A. Repetitive manufacturing B. Job shop production C. Semi-repetitive batch manufacturing D. None of the above

6. With regards to suppliers, lean systems typically require: A. Delivery of large lots at frequent 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

7. Reducing setup time is important because it: A. Increases available capacity B. Increases flexibility to meet schedule changes C. Reduces inventory D. Both a and b E. Both b and c F. a, b, and c

8. Given the following information pertaining to item AX143, determine the appropriate number of kanban cards that should be used to support production.

Demand rate = 500 units/week Lead time = 2 weeks Safety Stock = 30 percent Size of Container = 5 units A. 260 units B. 200 units C. 150 units D. 250 units

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Chapter 07 - Lean Thinking and Lean Systems

9. Which of the following is not required for a lean system?

A. Flexible workforce B. A Type II MRP system C. A stable master schedule D. Kanban pull system

10. If a work center has no empty containers, the workers at the work center will do which of the following?

A. Continue to produce as much inventory as they can B. Produce enough inventory to meet the following day's demand C. Produce enough inventory to satisfy the master production schedule D. Stop production

11. The ideal setup time for a lean system is: A. 5 minutes B. The time it takes the line to get ready C. 0 minutes D. 1 hour

12. The ideal lot size for a lean system is: A. Infinite B. One C. The capacity of the machine D. Variable according to the production requirements E. None of the above

13. The time it takes a container to complete an entire circuit consists of: A. Move time, time used, and wait time B. Wait time, run time, setup time, and idle time C. Fill time, wait time, move time, time used, and time to be returned to be filled again D. None of the above

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Chapter 07 - Lean Thinking and Lean Systems

14. If it takes 100 minutes to complete a circuit, demand at the next work center is 5 parts per minute, and a container will hold 20 parts, how many containers are required?

A. 25 B. 5 C. 40 D. 20

15. If a manufacturer has daily requirements for products A, B and C of 360, 100, and 300, respectively, then the daily schedule will call for the following amounts of each product to be produced per cycle: A. | (36)A (10)B (30)C | B. | (18)A (5)B (15)C | C. | (72)A (20)B (60)C | D. | (18)A (10)B (30)C |

16. How many cycles are required each day for the above daily requirements?

A. 16 B. 10 C. 20 D. 5

17. The principal objective of a lean system is: A. Worker participation B. Reduction of inventory C. Reduction of setup times D. Improve the ROI of the firm

18. Why is production leveled in a lean system?

A. To create a uniform workload on all work centers B. To allow for production of safety stock C. To signal the need for more parts D. To increase the time for scheduled maintenance

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Chapter 07 - Lean Thinking and Lean Systems

19. Reduction of setup time is accomplished by separating internal and external setups and: A. Reducing inventory B. Implementing a Kanban system C. Converting internal setup time to external setup time D. Reducing lot sizes

20. External setup time refers to: A. The time it takes workers to set up a machine during scheduled maintenance B. The time to complete setup activities that do not require that the machine be stopped C. The time it takes equipment vendors to set up the machine D. None of the above

True / False Questions

21. External setups refer to actions that require stoppage of the production process.

True False

22. According to the lean philosophy, it is required to maintain a stable master production schedule to reduce the work-in-process inventories.

True False

23. Value stream maps are similar to flowcharts and are used for identifying the waste and non-value-added steps in the current process.

True False

24. Lean is an example of a pull system while lean thinking is an example of a push system.

True False

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Chapter 07 - Lean Thinking and Lean Systems

25. A Kanban card system finds good utility in a job shop type of production process in regulating the workflow through the shop.

True False

26. Kaizen events typically take between 1 to 2 months.

True False

27. One-touch setups could require as long as 9 minutes to perform.

True False

28. With lean thinking, a company's operations layout should evolve to a cellular manufacturing layout.

True False

29. The key to reducing inventory is reducing lead-time.

True False

30. Poka-yoke is another term for stabilizing the master schedule.

True False

31. Takt time is calculated by taking demand over some period divided by the available time for production during that period.

True False

32. When kanban is used, only the final assembly department will receive a schedule from the dispatching office.

True False

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Chapter 07 - Lean Thinking and Lean Systems

33. "Gemba" refers to data collection using the company's information system.

True False

34. The Japanese term for waste is "gemba."

True False

Essay Questions

35. What are the five essential elements of lean thinking? In your own words, provide a road map for implementing lean thinking in a manufacturing or service operations.

36. What are the eight forms of waste?

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Chapter 07 - Lean Thinking and Lean Systems

Chapter 07 Lean Thinking and Lean Systems Answer Key

Multiple Choice Questions

1. Under lean, the ROI is increased by: A. An increase in revenues B. Cost reductions C. Fewer investments D. Both a and b E. Both b and c F. a, b, and c

Difficulty: Moderate

2. Which of the following is not an element of lean?

A. Small-lot production B. Modularized master schedule C. Multifunction workers D. Kanban pull system E. Perfect or nearly perfect quality

Difficulty: Easy

3. A kanban card is used to signal that: A. The next work center is stopped B. A materials handler has run out of parts C. A machine has broken down D. Parts are needed by the subsequent work center E. A machine is ready for preventive maintenance

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems

4. Lean emphasizes all of the following except: A. Setup time reductions B. Cross training of workers C. Lot size reduction D. Elimination of waste E. Supplier development F. Increased utilization of machines

Difficulty: Hard

5. For production control, lean pull systems are best suited for: A. Repetitive manufacturing B. Job shop production C. Semi-repetitive batch manufacturing D. None of the above

Difficulty: Moderate

6. With regards to suppliers, lean systems typically require: A. Delivery of large lots at frequent 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

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems

7. Reducing setup time is important because it: A. Increases available capacity B. Increases flexibility to meet schedule changes C. Reduces inventory D. Both a and b E. Both b and c F. a, b, and c

Difficulty: Easy

8. Given the following information pertaining to item AX143, determine the appropriate number of kanban cards that should be used to support production.

Demand rate = 500 units/week Lead time = 2 weeks Safety Stock = 30 percent Size of Container = 5 units A. 260 units B. 200 units C. 150 units D. 250 units

Difficulty: Moderate

9. Which of the following is not required for a lean system?

A. Flexible workforce B. A Type II MRP system C. A stable master schedule D. Kanban pull system

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems

10. If a work center has no empty containers, the workers at the work center will do which of the following?

A. Continue to produce as much inventory as they can B. Produce enough inventory to meet the following day's demand C. Produce enough inventory to satisfy the master production schedule D. Stop production

Difficulty: Easy

11. The ideal setup time for a lean system is: A. 5 minutes B. The time it takes the line to get ready C. 0 minutes D. 1 hour

Difficulty: Moderate

12. The ideal lot size for a lean system is: A. Infinite B. One C. The capacity of the machine D. Variable according to the production requirements E. None of the above

Difficulty: Moderate

13. The time it takes a container to complete an entire circuit consists of: A. Move time, time used, and wait time B. Wait time, run time, setup time, and idle time C. Fill time, wait time, move time, time used, and time to be returned to be filled again D. None of the above

Difficulty: Hard

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Chapter 07 - Lean Thinking and Lean Systems

14. If it takes 100 minutes to complete a circuit, demand at the next work center is 5 parts per minute, and a container will hold 20 parts, how many containers are required?

A. 25 B. 5 C. 40 D. 20

Difficulty: Easy

15. If a manufacturer has daily requirements for products A, B and C of 360, 100, and 300, respectively, then the daily schedule will call for the following amounts of each product to be produced per cycle: A. | (36)A (10)B (30)C | B. | (18)A (5)B (15)C | C. | (72)A (20)B (60)C | D. | (18)A (10)B (30)C |

Difficulty: Moderate

16. How many cycles are required each day for the above daily requirements?

A. 16 B. 10 C. 20 D. 5

Difficulty: Easy

17. The principal objective of a lean system is: A. Worker participation B. Reduction of inventory C. Reduction of setup times D. Improve the ROI of the firm

Difficulty: Easy

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Chapter 07 - Lean Thinking and Lean Systems

18. Why is production leveled in a lean system?

A. To create a uniform workload on all work centers B. To allow for production of safety stock C. To signal the need for more parts D. To increase the time for scheduled maintenance

Difficulty: Hard

19. Reduction of setup time is accomplished by separating internal and external setups and: A. Reducing inventory B. Implementing a Kanban system C. Converting internal setup time to external setup time D. Reducing lot sizes

Difficulty: Easy

20. External setup time refers to: A. The time it takes workers to set up a machine during scheduled maintenance B. The time to complete setup activities that do not require that the machine be stopped C. The time it takes equipment vendors to set up the machine D. None of the above

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems True / False Questions

21. External setups refer to actions that require stoppage of the production process.

FALSE

Difficulty: Moderate

22. According to the lean philosophy, it is required to maintain a stable master production schedule to reduce the work-in-process inventories.

TRUE

Difficulty: Easy

23. Value stream maps are similar to flowcharts and are used for identifying the waste and non-value-added steps in the current process.

TRUE

Difficulty: Easy

24. Lean is an example of a pull system while lean thinking is an example of a push system.

FALSE

Difficulty: Moderate

25. A Kanban card system finds good utility in a job shop type of production process in regulating the workflow through the shop.

FALSE

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems

26. Kaizen events typically take between 1 to 2 months.

FALSE

Difficulty: Moderate

27. One-touch setups could require as long as 9 minutes to perform.

FALSE

Difficulty: Moderate

28. With lean thinking, a company's operations layout should evolve to a cellular manufacturing layout.

TRUE

Difficulty: Moderate

29. The key to reducing inventory is reducing lead-time.

TRUE

Difficulty: Moderate

30. Poka-yoke is another term for stabilizing the master schedule.

FALSE

Difficulty: Moderate

31. Takt time is calculated by taking demand over some period divided by the available time for production during that period.

FALSE

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems

32. When kanban is used, only the final assembly department will receive a schedule from the dispatching office.

TRUE

Difficulty: Moderate

33. "Gemba" refers to data collection using the company's information system.

FALSE

Difficulty: Moderate

34. The Japanese term for waste is "gemba."

FALSE

Difficulty: Moderate

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Chapter 07 - Lean Thinking and Lean Systems Essay Questions

35. What are the five essential elements of lean thinking? In your own words, provide a road map for implementing lean thinking in a manufacturing or service operations.

The five basic elements of lean thinking are: (1) Specify precisely what it is about a product or service that creates value from the customer's perspective.

(2) Identify, study, and improve the value stream of the process for each product or service.

(3) Ensure that the flow within a process is simple, smooth, and error-free, thereby avoiding waste.

(4) Produce only what is pulled by the customer.

(5) Strive for perfection.

The Road Map for Lean Implementation should begin by identifying the value that the customer desires. The current state of the process should be identified in the next step. A value stream map is drawn describing the overall operations. This helps in eliminating the waste from the customer's point of view. The next step is to minimize the setup times or changeover times and rearrange the process in order to achieve a constant flow through the system. Then the process should be pulled from the customer's viewpoint. A lean thinking approach should strive for continuous improvement to meet the changing customer requirements.

(Refer to Section 7.2 of the text to augment this answer)

Difficulty: Moderate

36. What are the eight forms of waste?

Overproduction, waiting time, unnecessary transportation, excess processing, too much inventory, unnecessary motion, defects, and underutilization of workers.

(Refer to Section 7.2 of the text to augment this answer)

Difficulty: Moderate

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