lean process q&a chap015

8/10/2019 Lean Process Q&A Chap015

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Chapter 15 - Lean Operations

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Chapter 15

Lean Operations

True / False Questions

1. In lean operations, input resources arrive for processing just as the preceding batch is

completed.

TRUE

Difficulty: Easy

TLO: 1

Taxonomy: Knowledge

2. A functioning MRP system is required prior to adopting lean planning and control

systems.

FALSE

Difficulty: Easy

TLO: 5

Taxonomy: Knowledge

3. In a lean environment, anything not essential to the product or process is viewed as waste.

TRUE

Difficulty: Easy

TLO: 2Taxonomy: Knowledge


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4. The ultimate goal of lean operations is a system characterized by the smooth, rapid flow ofmaterials.

TRUE

Difficulty: Easy

TLO: 2

Taxonomy: Knowledge

5. Although inventories are maintained, the goal of lean operations is to minimize safety

stock.

FALSE

Difficulty: Easy


6. Lean operations are unable to easily handle changes of output or product mix.

FALSE

Difficulty: Easy


7. In the lean philosophy, producing more than two order quantities represents waste.

FALSE

Difficulty: Medium


8. The four building blocks of lean operations are: product design, process design,personnel/organizational elements, and manufacturing planning and control.

TRUE

Difficulty: Easy



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9. Fast and simple are two common threads that run through the four building blocks of leanoperations.

TRUE

Difficulty: Easy

TLO: 3

Taxonomy: Knowledge

10. Value-stream mapping is a technique focused on finding new ways of adding value for

critical stakeholders such as customers.

FALSE

Difficulty: Easy


11. If a firm's product mix is 60% of product A and 20% each of products B and C, an optimalmix-model production schedule would be successive sequences of AAABC.

FALSE

Difficulty: Medium

TLO: 3Taxonomy: Application

12. Quality and highly capable production systems are requirements for the successful

implementation of lean operations.

TRUE

Difficulty: Medium



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13. The small lot-sizing policy works well in a situation where both holding costs and setupcosts are high.

FALSE

Difficulty: Hard

TLO: 5

Taxonomy: Synthesis

14. The use of small lot sizes in lean operations is in conflict with the EOQ approach since

setup costs tend to be significantly higher than holding costs.

FALSE

Difficulty: Medium


15. A basic requirement for operating with low inventories in lean systems is that majorsystem problems must already have been solved and new problems will be solved as they

appear.

TRUE

Difficulty: HardTLO: 4Taxonomy: Knowledge

16. A benefit of small lot sizes in lean systems is that each product is produced lessfrequently.

FALSE

Difficulty: Easy

TLO: 4

Taxonomy: Knowledge


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17. In the lean philosophy, the larger the lot size, the easier it is to schedule.

FALSE

Difficulty: Easy


18. Setup time and its associated cost can often be reduced by the use of group technology.

TRUE

Difficulty: Medium

TLO: 4

Taxonomy: Knowledge

19. Lean systems often use layouts that are based on group technology product requirements.

TRUE

Difficulty: Medium

TLO: 5

Taxonomy: Knowledge

20. The goal of lean operations is to produce output using fewer resources than traditionalplanning systems.

TRUE

Difficulty: Easy

TLO: 2

Taxonomy: Knowledge

21. "Autonomation" indicates that the firm is attempting to reduce its dependence onautomated equipment.

FALSE

Difficulty: Easy



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22. "Preventive maintenance" is additional maintenance done immediately after a breakdownhas occurred to help prevent any further breakdowns.

FALSE

Difficulty: Easy

TLO: 3

Taxonomy: Knowledge

23. In the lean approach, inventories are reduced gradually, instead of eliminating inventories

as rapidly as possible.

TRUE

Difficulty: Easy


24. One problem with lean operations is that they can lead to much frustration anddisappointment of people on the shop floor due to the need for continuously monitoring and

expediting resource availability.

TRUE

Difficulty: MediumTLO: 6Taxonomy: Knowledge

25. A real advantage of the lean philosophy is the reduction of co-ordination effort required.

FALSE

Difficulty: Easy



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26. The lean philosophy recognizes that some work-in-process inventories are a necessaryinvestment to allow for smooth work-flow.

FALSE

Difficulty: Medium

TLO: 3

Taxonomy: Knowledge

27. Preventive maintenance will eliminate the need to carry supplies of spare parts.

FALSE

Difficulty: Hard


28. A fundamental tenet of the lean philosophy is that workers are paid based on seniority.

FALSE

Difficulty: Easy


29. In lean operations, a responsibility of the cross-trained worker is to check the quality of

the work of others.

TRUE

Difficulty: Medium


30. In lean operations, when work is completed at one work center, it is important toimmediately move the completed work to the next work center to minimize idle time.

FALSE

Difficulty: Medium



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31. In a "pull system," a quantity of inventory in front of a workstation indicates problems atthat workstation.

TRUE

Difficulty: Hard

TLO: 5

Taxonomy: Knowledge

32. Limited WIP lowers inventory carrying costs but reduces flexibility.

FALSE

Difficulty: Medium


33. Engineering changes can be very disruptive to smooth operations and should not be made

in the six month period following introduction of a new product.

FALSE

Difficulty: Medium


34. Kanban is the Japanese term for autonomation.

FALSE

Difficulty: Medium


35. Increased setup times equal increased work in process inventories.

TRUE

Difficulty: Medium



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36. Kanban focuses on specific part numbers; CONWIP does not.

TRUE

Difficulty: Hard


37. Lean systems typically require that suppliers be able to provide large lots at periodic

intervals.

FALSE

Difficulty: Medium


38. Lean purchasing requires frequent contract bidding by multiple sources to ensure the

buyer of competitive prices.

FALSE

Difficulty: Medium


39. One way of reducing the number of suppliers to the organization is to limit contacts to

only one or two tiers of suppliers.

FALSE

Difficulty: Easy



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40. One major difference between the use of kanban and MRP II in scheduling the products tobe built is that kanban is primarily a manual system while MRP II uses computers.

TRUE

Difficulty: Hard

TLO: 5

Taxonomy: Knowledge

41. A benefit of the lean philosophy is the flexibility to respond quickly to changing customer

requirements.

TRUE

Difficulty: Easy


42. A benefit of lean systems is that lead times are increased allowing more time forprocessing.

FALSE

Difficulty: Medium


43. A successful conversion to a lean system requires that every vendor use lean approaches

prior to the organization's implementation.

FALSE

Difficulty: Medium



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44. The single-minute exchange of die is a system for reducing defective product.

FALSE

Difficulty: Hard


45. In a balanced system cycle time is equal to Takt time.

TRUE

Difficulty: Hard

TLO: 5

Taxonomy: Knowledge

46. It is important to lower the water (inventory) completely to expose all the rocks

(problems).

FALSE

Difficulty: Medium


47. Successful lean implementation requires much more than slogans and idealistic goals such

as zero inventories and zero defects.

TRUE

Difficulty: Easy


48. Lean concepts include large lots to take advantage of the economies of scale.

FALSE

Difficulty: Easy



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49. Value-stream mapping is concerned strictly with the flow of materials through aproduction system.

FALSE

Difficulty: Medium

TLO: 7

Taxonomy: Knowledge

Multiple Choice Questions

50. For a company with a product mix of 40% of product A and 30% each of products B andC, which of the following mixed-model sequences most reflects the lean philosophy?

A.AABBCCAABC

B.ABCABCABCAC.AAAABBBCCC

D.BCABCABCAB

E.BBBAACCCAA

Difficulty: MediumTLO: 5

Taxonomy: Application

51. The lean philosophy suggests that workers are

A.Assets

B.Liabilities

C.InterchangeableD.Replaceable

E.To be phased out

AACSB: RT


Taxonomy: Knowledge


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52. 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 systemD.no setup timesE.all of the above

Difficulty: Medium

TLO: 2

Taxonomy: Knowledge

53. Which one of the following is not one of the building blocks that is the foundation of the

lean philosophy?

A.product designB.process design

C.personnel/organizational elementsD.manufacturing planning and control

E.kanban

Difficulty: Medium


54. Building up an inventory of standard parts or modules instead of immediately producingthe finished end items is the essence of:

A.delayed differentiation

B.kanbanC.autonomationD.andon

E.matrix management

Difficulty: Medium

TLO: 3

Taxonomy: Knowledge


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55. Which of the following would you not expect to see in a lean environment?A.a flexible system

B.minimum inventory

C.little wasteD.reduced setup times

E.a significant number of daily schedule changes

Difficulty: Medium

TLO: 3

Taxonomy: Knowledge

56. 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 materialsC.making workers responsible for producing high quality

D.A, B and CE.100% inspection of raw materials, work-in-process and finished goods

Difficulty: Easy


57. 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.

Difficulty: Medium



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58. In the lean philosophy, the ideal lot size is:A.the economic order quantity

B.the economic run size

C.one unitD.the capacity of the standard containerE.N=(DT(1+X))/C

Difficulty: Easy

TLO: 3

Taxonomy: Knowledge

59. Which of the following does not contribute to reduced setup time and cost?

A.standardized setup tools

B.standardized setup equipmentC.custom setup procedures for each product

D.use of multipurpose equipment or attachmentsE.use of group technology

Difficulty: Medium


60. A conveyance __________ signals parts movement.A.RequestB.Routing

C.Bar code

D.KanbanE.Kazian

Difficulty: Medium



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61. The term that refers to the automatic detection of defects is:A.kaizen

B.kanban

C.autonomationD.automationE.100% inspection

Difficulty: Easy

TLO: 3

Taxonomy: Knowledge

62. 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.

Difficulty: Hard


63. Which of the following is not characteristic of preventive maintenance in lean systems?A.maintaining equipment in good operating conditionB.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 investmentE.perceiving breakdowns as an opportunity for improvement

Difficulty: Hard



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64. The Five S's don't includeA.SortB.Straighten

C.SanitizeD.SweepE.Standardize

Difficulty: Hard

TLO: 3

Taxonomy: Knowledge

65. The Kaizen philosophy applies to

A.Employee development

B.Safety stockC.Waste

D.Supply Chain Management

E.MRP III

Difficulty: Medium


66. A 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 stationC.a worker has run out of parts needed for further processing

D.a machine has broken down and needs immediate attention

E.a machine is ready for preventive maintenance

Difficulty: Hard

TLO: 5

Taxonomy: Knowledge


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67. 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 purchaseD.long-term relationships and commitmentsE.the lowest price possible

Difficulty: Medium

TLO: 5

Taxonomy: Knowledge

68. 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 co-workers, essentially other departments of our organization.

D.Queues are a necessary investment.E.all of the above

Difficulty: Medium


69. The activities controlled in the same way by kanban and MRP II is the determination of:A.rates of output

B.products to be built

C.materials required

D.capacity requiredE.feedback information

Difficulty: Hard



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70. Process design supporting lean doesn't includeA.Production flexibility.

B.Duplicate facilities.

C.Setup time reduction.D.Minimal inventory storage.E.Small lot sizes

Difficulty: Hard

TLO: 3

Taxonomy: Knowledge

71. Which of the following questions is not answered by value stream mapping?

A.Where does waste occur?

B.Which processes or sub-processes 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?

Difficulty: Easy

TLO: 7

Taxonomy: Knowledge

72. 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 above

Difficulty: Medium

TLO: 5

Taxonomy: Knowledge


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73. A potential obstacle to conversion to a lean system is:A.lack of management commitment

B.lack of worker cooperation

C.supplier resistanceD.all of the aboveE.insufficient space to store the increased inventories

Difficulty: Easy

TLO: 6

Taxonomy: Knowledge

74. A system of lights used at each workstation to signal problems or slowdowns is:

A.command and control center

B.automationC.andon

D.pull systemE.kanban

Difficulty: Easy


75. Which of the following contributes to the competitive advantage enjoyed by firms usinglean production?A.Backup employees to cover for absenteeism

B.100% inspection to remove defects

C.Dedicated equipment to reduce unit costsD.Safety stocks to prevent stock-outs

E.Greater flexibility to cope with change

Difficulty: Medium



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76. An operations strategy reflecting the lean philosophy of production should recognize thatlean:

A.is most suited for non-repetitive manufacturing

B.cannot be implemented sequentiallyC.requires a wholesale commitment from the outset

D.may provide a competitive advantage

E.all of the above

Difficulty: Hard

TLO: 4

Taxonomy: Knowledge

77. With regard to suppliers, lean systems typically involve:

A.delivery of large lots on short noticeB.the highest quality at the lowest price

C.long-term relationshipsD.multiple suppliers to assure continuous availability

E.dedicated staging areas for material

Difficulty: Medium


78. A common objective of both MRP and the lean philosophy is to:A.smooth production

B.minimize inventory

C.obtain high qualityD.reduce overheadE.eliminate inventory

Difficulty: Medium



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79. 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%)D.balanced and rapid flowE.all of the above

Difficulty: Medium

TLO: 2

Taxonomy: Knowledge

Essay Questions

80. The All Seasonings Company uses 3,200 glass jars at one of its jar-filling workstationseach eight hours of production. The cycle time for a standard container, which holds 90 jars,

averages 45 minutes. If management uses an efficiency factor of twenty percent, how many

containers should be used?

N = ?

D = 3200/8 = 400 jars per hour

T = 45/60 = .75 hourX = .20

C = 90 jars

AACSB: AS

Difficulty: Medium

TLO: 5



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81. The Four Star Publishing Company uses sixty reams of paper each hour at one of its highspeed printing stations. The cycle time for a standard container, which holds 15 reams of

paper, averages forty minutes. If management has decided to use three containers, what

efficiency factor was applied?

X = ?

N = 3 containers

D = 60 reams per hourT = 40/60 = 2/3 hour

C = 15 reams

AACSB: ASDifficulty: Medium

TLO: 5


82. A production system uses kanban cards to control production and movement of parts. One

work center uses an average of 40 pieces per hour of a certain part. Standard containers hold

10 parts. The cycle time for parts containers is about 36 minutes. Management has assigned

an efficiency factor of .20 to this work center. How many containers should be used tosupport this operation?

N = ?D = 40/hour

T = 0.6 hours, X = 0.20 and C = 10, therefore,

AACSB: AS




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83. A production cell uses 240 pounds of plastic resin each 8-hour day. Resin is transported indrums that hold 100 pounds each. The material is obtained from a nearby supplier, and has a

12-hour cycle time. An efficiency factor of .15 has been assigned to this cell. What is the

optimum number of containers to support this operation?

N = ?

D = 240/8 = 30 pounds/hour

T = 12 hoursC = 100 pounds

X = 0.15

AACSB: AS



lean process q&a chap015

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