Strayer University

BUS 430

TRUE/FALSE

1)Lean enterprise refers to approaches that focus on the elimination of defects and errors throughout the value chain.

 

                                           

 

2. In lean thinking, waste need not be classified as simply material waste such as scrap and defective parts.

 

                                           

 

3. Synchronization of the value chain is a lean approach to increasing speed and response.

 

                                           

 

4. According to the Toyota Motor Company, waiting time is a necessary evil in production and is not classified as waste.

 

                                           

 

5. The 5Ss focus on improving waste generated by inefficient transportation.

 

                                           

 

6. Firms use the “5S” principles to create a clean and organized work environment.

 

                                           

 

7. A clean and organized work area is an important principle of lean thinking.

 

                                           

 

8. Single minute exchange of dies (SMED) frees up capacity for other productive uses.

 

                                           

 

9. Large batches often provide economies of scale and helps firms match inventory to market demand.

 

                                           

 

10. To accomplish single piece flow, a manufacturer needs the ability to change between products quickly and inexpensively.

 

                                           

 

11. Lean operating systems seek to apply the principles of continuous flow to the production of discrete parts by reducing batch size, ideally to a size of one.

                                           

12. Lean Six Sigma is simply the union of lean approaches with quality improvement techniques, each of which has been used independently in other applications.

 

                                           

 

13. The goal of total productive maintenance is to minimize the costs associated with routine maintenance activities.

 

                                           

 

14. A goal of total productive maintenance is to have zero accidents in the entire life cycle of the operating system.

 

                                           

 

15. Lean principles are of primary benefit to manufacturers and provide little value to service organizations.

 

                                           

 

16. In a JIT system, the computer inventory data is the interface and control point between customers and supply cycles.

 

                                           

 

17. In a push system, finished goods inventory is produced in advance of customer demand using a forecast of sales.

 

                                           

 

18. JIT systems are based on the concept associated with pull systems rather than push systems.

 

                                           

 

19. Kanban is a Japanese term for elimination of waste.

 

                                           

 

20. The number of Kanban cards is directly proportional to the amount of work-in-process inventory.

 

                                           

 

21. Six Sigma addresses visible problems in processes; lean production is more concerned with less visible problems.

 

                                           

 

22. Lean production is focused on efficiency by reducing waste and improving process flow, while Six Sigma is focused on effectiveness by reducing errors and defects.

 

                                           

 

23. Production Kanbans trigger the movement of parts.

                                           

 

24. Total Productive Maintenance (TPM) strives to relieve machine operators of routine maintenance so that they can focus entirely on being productive.

 

                                           

 

25. When producing a broad goods or service mix with diverse requirements on common equipment, the ideal strategy is to run large batches.

 

                                           

 

 

MULTIPLE CHOICE

 

1. Which of the following is not a basic principle of a lean operating system?
   1. Elimination of waste
   2. Batching
   3. Increased speed and response
   4. Improved quality

 

                                           

 

2. According to the Toyota Motor Company, which of the following is not one of the seven major waste categories?
   1. Overproduction
   2. Transportation
   3. Motion
   4. Single-piece flow

 

                                           

 

3. Long lead-times and higher work-in-process is most closely related to which of Toyota's "Seven Major Waste Categories?"
   1. Overproduction
   2. Single-piece flow
   3. Waiting time
   4. Transportation

 

                                           

 

4. Which of the following is not one of the 5Ss?
   1. Synchronize
   2. Standardize

1. 3. Shine
   4. Sustain

 

                                           

 

5. In the 5Ss, items identified as unnecessary and thus removed from a workplace would be included with which S?
   1. Sort
   2. Synchronize
   3. Shine
   4. Standardize

 

                                           

 

6. Quick setup or changeover of tooling and fixtures is associated with        .
   1. Visual controls
   2. Single minute exchange of dies
   3. 5Ss
   4. Six Sigma

 

                                           

 

7. Total Production Maintenance (TPM)
   1. Puts total responsibility on maintenance workers
   2. Puts total responsibility on equipment operators
   3. Eliminates all down time
   4. Employees preserve and protect their equipment

 

                                           

 

8. Total productive maintenance (TPM) seeks to do all of the following except       .
   1. Maximize equipment effectiveness
   2. Create worker ownership
   3. Foster continuous improvement efforts
   4. Enable multiple products in small batches to be run on the same equipment

 

                                           

 

9. Quality at the source requires
   1. Starting with a plan

1. 2. Having reliable suppliers
   3. Doing it right the first time
   4. Having a good design

 

                                           

 

10. Toyota classified waste into seven major categories. Those categories include all of the following except
    1. Motion
    2. Ordering
    3. Inventory
    4. Waiting

 

                                           

 

11. Which of the following is least related to a push system?
    1. Maximum customer responsiveness
    2. Predefined schedule
    3. Finished goods inventory
    4. Based on forecast

 

                                           

 

12. Which of the following is least related to a pull system?
    1. Building inventory
    2. Final assembly schedule
    3. Real time information
    4. Sales rate

 

                                           

 

13. A withdrawal Kanban
    1. Authorizes production
    2. Authorizes suppliers to produce
    3. Authorizes the transfer of an empty container
    4. Authorizes shipping to customers

 

                                           

 

14. The number of Kanban cards is dependent on all of the following except

1. 1. Average daily demand rate
   2. Setup time
   3. Part waiting time
   4. Safety stock

 

                                           

 

15. Which one of the following statements is true concerning Lean Six Sigma?
    1. Lean principles focus on advanced statistical methods.
    2. Lean principles have been developed over a sixty year plus period of time.
    3. Lean principles include the 5Ss framework and practices.
    4. Six Sigma and lean principles are not related − they are separate bodies of knowledge.

 

                                           

 

16. Southwest Airlines illustrates the application of "lean principles" when it
    1. reduces airplane turnaround time at airport gates.
    2. assigns airplane seats.
    3. serves all passengers in-flight dinners.
    4. requires a change of ticket fee for missing a scheduled flight.

 

                                           

 

17. Which one of the following statements is true?
    1. Postponement is the process of delaying orders from suppliers because it is very difficult to order from geographically dispersed businesses.
    2. General Motors supply chain is a good example of a push system.
    3. Dell Computers supply chain is a good example of push system.
    4. Flexibility and responsive service are top priorities compared to low cost in an efficient supply chain.

 

                                           

 

18. Principles of lean operating systems include all of the following except
    1. Eliminate waste
    2. Reduce workforce
    3. Increase speed and response
    4. Reduce cost

                                           

 

19. Which of the following "lean" ideas is false?
    1. Activities not adding value are a waste.
    2. Accidents are a form of waste.
    3. A pull system produces waste.
    4. Overproduction is a form of waste.

 

                                           

 

20. Ford Motor Company has decided to switch to a pull system of manufacturing and distribution for its vehicles. Which one of the following is most likely to occur?
    1. Inventory levels will increase.
    2. Component parts and subassemblies will be replenished only when needed.
    3. Dealer parking lot space will need to be increased.
    4. Finished goods inventory will decrease, but raw materials and work-in-process inventories will increase.

 

                                           

 

21. In a Kanban system, the numerator of the formula K =[d(p + w)(1 + ?)]/C is analogous to
    1. demand during the lead time only in a fixed quantity inventory system.
    2. safety stock only in a fixed period inventory system.
    3. the order up-to-level (M) in a fixed period inventory system.
    4. the reorder point (r) in a fixed quantity inventory system.

 

                                           

 

22. ABC Manufacturing uses a Kanban system for a component. The daily demand is 800 units. Each container has a combined waiting and processing time of 0.34 days. If the container size is 50 and efficiency (safety) factor is 9 percent, how many Kanban card sets should be authorized (round up)?
    1. 5 sets
    2. 6 sets
    3. 7 sets
    4. 8 sets

 

                                           

 

23. Which one of the following statements is true?
    1. The heijunka system is a system of boxes much like in a mailroom set of boxes attached to a wall used to smooth production outputs.
    2. Producing goods early is a principle of lean.

1. 3. A university publication printed with 100% post-consumer recycled fiber is an example of total productive maintenance practice.
   4. Preventive maintenance is not a part of lean principles and practices.

 

                                           

 

SHORT ANSWER

1. Define lean enterprise and the four principles of lean operating systems.

 

 

2. Discuss the seven major categories of waste as defined by Toyota.

 

 

 

3. Explain the purpose of visual controls and give examples.

 

 

 

4. Explain the concept of Single Minute Exchange of Die (SMED).

 

 

 

 

5. Contrast batching with single-piece flow.

 

 

 

6. Explain the 5Ss.

 

 

 

7. How does Total Productive Maintenance (TPM) affect lean operating systems?

 

 

 

8. Discuss the differences between lean production and Six Sigma.

 

 

 

9. Compare and contrast a push system vs. a pull system.

 

 

 

 

10. Define a Kanban. Describe how it helps execute a pull system.

 

 

 

 

PROBLEM

 

1. Hinge Manufacturing Company employs a Kanban system for a component part. The daily demand is 900 hinges. Each container has a wait time of 0.05/day, and a processing time of 0.37 days. The Container size is 60 hinges and the safety factor (?) is 10%.
   1. How many Kanban card sets should be authorized?
   2. What is the maximum inventory of this hinge in the system?

2. A manufacturer of automobile engines is designing a new Kanban system for engine #321. The

demand for #321 is 75/day and they are built in groups of 8. The total process and wait time is 3 days. The manager wants an alpha (?) of 2 or 200%. How many Kanbans are required?

3. A company is using Kanban containers. There are two adjacent work centers, a downstream (using) and an upstream (producing) one. The using work center has a production rate of 200 parts per day and each container holds 20 parts. It takes .5 days for a container to make the entire cycle from the time it leaves the upstream center until it is returned, filled with production, and leaves again. The manager wants a safety factor (?) of 20%. The company is interested in reducing the number of containers.
   1. What is the number of containers currently in use?
   2. If the number of parts a container holds is increased to 24 parts, how many containers are needed?
   3. If the company wants the number of containers (holding 20 parts each) to be 5, what must the safety factor become?

 

4. A company is using a Kanban system with 2 containers, each holding 50 parts, between a downstream (using) and an upstream (producing) work center. The using work center can handle 250 jobs per day. The average elapsed time for the entire cycle is currently .25 days. The company is concerned with the safety factor for the operation and the size of the containers.

 

1. 1. What is the efficiency rating of the current operation?
   2. If the company decides to use only one container, how many parts must it hold?
   3. If the safety factor is changed to .12 and there are still 2 containers, how many parts must each container now hold?

 

5. A manufacturing company is using a two-container Kanban system between a downstream (using) and an upstream (producing) work center. Each container holds 25 parts. The using work center can handle 100 parts per day. The average elapsed time for the entire cycle is currently .40 days. The company is concerned about the efficiency of the operation.

 

1. 1. What is the safety factor for the current operation?
   2. What is the maximum authorized inventory for this part?
   3. If the number of containers is reduced to one, how many parts must it hold?
   4. If the efficiency is changed to .10 and the number of parts per container is increased to 44, how many containers will be needed?