Lean final exam answers PDF

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TEST BANK QUESTIONS for John Nicholas “Lean Production for Competitive Advantage”

Note: The number at the beginning of each question is the page number where the question and answer originate. In the multiple-choice questions the asterisk (*) indicates the correct answer. For the true/false questions the correct response follows the question statement.

Chapter 1 Multiple-Choice 2. In contrast to traditional manufacturers lean firms rely more on which of the following? Proper placement of equipment Smaller manufacturing units Improved focus employee teams *All of the above None of the above 2. In contrast to traditional manufacturers lean firms rely more on which of the following? *Group technology Computer Aid Design (CAD) Computer Aided Manufacturing (CAM) All of the above None of the above 2. In contrast to traditional manufacturers lean firms rely more on which of the following? Computer Aid Design (CAD) Computer Aided Manufacturing (CAM) Robotics All of the above *None of the above 3. Lean production can also be referred to as which of the following? CAD *JIT CAM All of the above None of the above 9. The Toyota Production System includes which of the following topics/features? Reduced setup times

Small lot production One-piece flow *All of the above None of the above 10. The Toyota Production System includes which of the following topics/features? Employee involvement Employee empowerment Quality at the source *All of the above None of the above 10-11. The Toyota Production System includes which of the following topics/features? Preventive maintenance Pull production Standard work *All of the above None of the above

Chapter 1 True/False 2. To make things (i.e., products) faster lean firms rely on robotics. False 2. To make things (i.e., products) faster traditional firms rely on robotics. True 2. To make things (i.e., products) faster lean firms rely on location of facilities. False 2. Lean firms consider agility an integral part of quality and delivery capability. True 2. To make things (i.e., products) better traditional manufacturers rely on CAD. True 3. Lean production is management that focuses the organization on continuously indentifying and removing sources of waste so that processes are continuously improved. True 8. The Toyota Production System can be viewed as the prototype for lean production. True 10. Halting a production line under a lean management approach is called, “JIT”.

False 10. Halting a production line under a lean management approach is called, “Jidoka”. True 11. To reduce production wastes in the flow of materials, chief production engineer Taiichi Ohno developed the “pull production” system. True 11. To coordinate the flow of materials between stages of production, chief production engineer Taiichi Ohno developed the “just-in-time” system. False 11. To coordinate the flow of materials between stages of production, chief production engineer Taiichi Ohno developed the “Kanban” system. True

Chapter 2 Multiple-Choice 28. The PDCA cycle discussed in the book stands for which of the following? Plan-Done-Choice-Act Plan-Do-Cycle-Action *Plan-Do-Check-Act All of the above None of the above 28. The PDCA cycle is called which of the following? *Deming cycle JIT processing cycle Discontinuity All of the above None of the above 28. The PDCA cycle is called which of the following? Ohno cycle *Shewhart cycle Discontinuity All of the above None of the above

29. Under a PDCA cycle one must collect data on which to find the root cause of a production problem. Which of the following is a term used to describe the firsthand observation at the source or location of the problem? *Gemba JIT Kaizen All of the above None of the above 29. Under a PDCA cycle one must collect data on which to find the root cause of a production problem. Which of the following is a term used to describe the firsthand observation at the source or location of the problem? Deming solution method Concurrent engineering Kaizen All of the above *None of the above 29. In the plan stage of the PDCA cycle a 5W1H principle refers to which of the following activities? Who What Where *All of the above None of the above 29. In the plan stage of the PDCA cycle a 5W1H principle refers to which of the following activities? When Why How *All of the above None of the above 37-38. Kaizen projects that generally follow the PDCA procedure rely on data collection and analysis techniques called the seven basic problem-solving tools. Which of the following is one of these seven tools? Check sheet Histogram Pareto analysis *All of the above None of the above 40-42. Kaizen projects that generally follow the PDCA procedure rely on data collection and analysis techniques called the seven basic problem-solving tools. Which of the following is one of these seven tools? Scatter diagram

Process flow chart Cause-and-effect analysis *All of the above None of the above 37-38. Kaizen projects that generally follow the PDCA procedure rely on data collection and analysis techniques called the seven basic problem-solving tools. Which of the following is one of these seven tools? Check box Statistical diagram *Run diagram All of the above None of the above

Chapter 2 True/False 22. Incremental improvement is referred to as “kaizen”. True 29. The planning step of the PDCA cycle can involve the 5W1H principle. True 30. The 5W1H principle is the same as the Five-Why Process. True 31. There is no difference between value analysis and value engineering. False 33. There is no difference between concurrent engineering and reengineering. False 40-43. A run diagram and a scatter diagram provide the same basic information. False 42-43. To identify all possible causes of possible contributors to a given production problem one of the problem solving and improvement tools of PDCA is a run diagram. False 38-42. To identify all possible causes of possible contributors to a given production problem one of the problem solving and improvement tools of PDCA is a Pareto analysis. False

44. Value stream mapping (VSM) uses standard icons and diagramming principles to visually display the steps in the process and material and information flowing through it, from start to finish. True 46. “Nemawashi” refers to a process of circulating a plan or proposal among all the people affected by it or who must approve it. True

Chapter 3 Multiple-Choice 60. The chapter listed Toyota’s seven wastes that organizations should seek to eliminate include which of the following wastes? Product defects Transportation Inventory *All of the above None of the above 60. The chapter listed Toyota’s seven wastes that organizations should seek to eliminate include which of the following wastes? Overproduction Processing Motion *All of the above None of the above 63. Waste in waiting can include which of the following? Waiting for orders Waiting for parts Waiting for materials *All of the above None of the above 63. Waste in waiting can include which of the following? *Waiting items from preceding processes Waiting for a deadline to pass Waiting for to see if the boss shows up for work All of the above None of the above 63. A useful concept in identifying waste in motion is work content. Which of the following is the ratio that can be used to define work content?

Motion/work *Work/motion Waiting time + work time Work time + (Motion/work) None of the above 65. The chapter listed Canon Corporation’s nine wastes that organizations should seek to eliminate. Which of the following are Canon’s wastes? Defects Expense Indirect labor *All of the above None of the above 65. The chapter listed Canon Corporation’s nine wastes that organizations should seek to eliminate. Which of the following are Canon’s wastes? Operations Startup Equipment *All of the above None of the above 65. The chapter listed Canon Corporation’s nine wastes that organizations should seek to eliminate. Which of the following are Canon’s wastes? Green programs *Planning Design for environment (DFE) All of the above None of the above 66. Which of the following are lean principles? *Simplification Concurrent engineering Design for environment (DFE) All of the above None of the above 69-75. Which of the following are lean principles? Cleanliness Visibility Cycle timing *All of the above None of the above 71. Which of the following is a part of the Five Ss?

Seiri Seition Seiso *All of the above None of the above 71. The proper arrangement of a workplace is referred to as which of the following 5 Ss program? *Seiri Seition Seiso Seiketsu Shisuke 71. Which of the following 5 Ss refers to cleanliness? Seiri Seition *Seiso Seiketsu Shisuke 71. Which of the following 5 Ss refers to neatness? Seiri Seition Seiso *Seiketsu Shisuke 71. Which of the following 5 Ss refers to orderliness? Seiri *Seition Seiso Seiketsu Shisuke

Chapter 3 True/False 58. Value added is the concept that every activity and element of a system (materials, humans, time, space or energy) should add value to the output of the system. True 59. Employee involvement is fundamental to valued added improvement efforts.

True 60. Toyota’s strong advocacy of eliminating waste is called, “kaizen”. False 60. Toyota’s strong advocacy of eliminating waste is called, “muda”. True 61. In Toyota’s seven wastes products or services should be done right the first time. True 64. Work and motion are really the same. False 65. Lean to green programs can reduce air pollution. True 65. Lean to green programs require the use of design for environment (DFE) programs. False 65. Lean to green programs can utilize design for disassembly efforts. True 79. Variation (variability) is the amount by which something differs from some nominal value (standard, target, or expected). True

Chapter 4 Multiple-Choice 90. Which of the following are dimensions of quality mentioned in the book? Performance Features Conformance *All of the above None of the above 90. Which of the following are dimensions of quality mentioned in the book? Defect prevention Defect detection *Aesthetics All of the above None of the above

93. The TQM integrated framework presented in the book includes coverage into which of the following business functional areas? Product design and engineering Customer service External suppliers *All of the above None of the above 93. The TQM integrated framework presented in the book includes coverage into which of the following business functional areas? Accounting *Purchasing Economics All of the above None of the above 97-98. Which of the following terms are represented by letters in the quality methodology referred to as DMAIC? Measure Analyze Improve *All of the above None of the above 97-98. Which of the following terms are represented by letters in the quality methodology referred to as DMAIC? Interpret Manufacture Develop All of the above *None of the above 98. Which of the following are Six Sigma experts’ certification in the DMAIC process? *Green belts Red belts Blue belts All of the above None of the above 98. Which of the following are Six Sigma experts’ certification in the DMAIC process? Master red belts *Master black belts Purple belts All of the above None of the above

Chapter 4 True/False 90. The customer’s perspective of quality on how well the product compares to what the customer expects from it, is called “fitness for use”. True 91. The term “quality of design” represents the ability of a product as designed to satisfy or exceed customer expectations. True 91. The term “quality of conformance” represents the ability of a product as designed to satisfy or exceed customer expectations. False 91. The term “total quality management” (TQM) refers to a management approach to focus all functions and levels of an organization on quality and continuous improvement. True 94. Design for manufacturing and assembly (DFMA) is among the approaches for integrating customer requirements and production process issues into product designs. True 94. Concurrent engineering is among the approaches for integrating customer requirements and production process issues into product designs. True 96. Toyota first used the term “Six Sigma”. False 101. A good example of process capability is visual management. False 101. A good example of non-statistical process control is visual management. True

Chapter 5 Multiple-Choice 112. Setup costs in lot sizing include which of the following items? Cost of production run changeovers Cost of scrap Cost of lost production while a process is being changed *All of the above

None of the above 112. Setup costs in lot sizing include which of the following items? Cost of mortgage Cost of utilities Cost of pilferage All of the above *None of the above 112. Setup costs in lot sizing include which of the following items? Cost of insurance * Cost of lost production while a machine is being changed Cost of maintenance All of the above None of the above 112. Holding costs in lot sizing include which of the following items? Cost of rent Cost of storage Cost of tracking inventory *All of the above None of the above 112. Holding costs in lot sizing include which of the following items? Cost of monitoring inventory Opportunity cost of money tied up in inventory Cost of damage *All of the above None of the above 113. Which of the following were identified as a type or kind of lot? Process batch Order quantity Transfer batch *All of the above None of the above 116. Which of the following are assumptions that must hold true in order for the EOQ model to accurately determine the cost minimize order quantity? Demand is a variable value *Setup costs are fixed Stockouts can be allowed All of the above None of the above

116. Which of the following are assumptions that must hold true in order for the EOQ model to accurately determine the cost minimize order quantity? *Unit purchase price or manufacturing cost is fixed Unit carrying cost can be variable Demand is dependent All of the above None of the above 126. Which of the following is the term used when excess inventory is held between stages of a process to avoid running short? Demand inventory Setup inventory *Buffer stock All of the above None of the above

Chapter 5 True/False 111. In small lot production lot sizes must be determined. The terms “lot” and “batch” are interchangeable. True 111. Determining the right size lot is called lot sizing. True 112. Setup costs are not important in actually determining a lot size for a production run. False 113. A quantity of items manufactured as the result of a single setup is referred to as a “production batch”. True 113. A quantity of items manufactured as the result of a single setup is referred to as a “process batch”. True 113. When a quantity of materials are purchased from a supplier it is referred to as a “purchase quantity”. True 113. When a quantity of materials are purchased from a supplier it is referred to as a “order quantity”. True

113. A lot shipped between a supplier and customer is referred to as a “delivery quantity”. True 114. The period order quantity (POQ) method can increase the number of production setups. False 114. Independent demand inventory is dependent on dependent demand inventory. False 115. The intersection of the total carrying cost function with the total setup function can be used in EOQ analysis to define the TQM optimal point. False 117. The EMQ model is more applicable than the EOQ model for determining the lot size of production batches. True 125. A bottleneck operation is one where the production capacity is more than the demand placed upon it. False

Chapter 6 Multiple-Choice 137. Which of the following are categories of benefits listed in the book of simplifying setups and reducing setup times? Quality Costs Flexibility *All of the above None of the above 137. Which of the following are categories of benefits listed in the book of simplifying setups and reducing setup times? Worker utilization Capacity and lead times Process variability *All of the above None of the above 139-142. Which of the following are stages in the SMED methodology for setup reduction? Convert external steps to internal *Improve all aspects of the setup operation In Stage 1, identify only internal steps

All of the above None of the above

Chapter 6 True/False 138. Shigeo Shingo was a lean management consultant to Honda Corporation. False 139. SMED stands for “Single Manufacturing Exchange of Dies”. False 144. Under lean checklists are maintained by operators and other responsible for setups. True 139. Sometimes using multiple workers to do setup tasks simultaneously can increase the internal setup of equipment (i.e., when the equipment is turned off). False 139. Sometimes using multiple workers to do setup tasks simultaneously can reduce the internal setup of equipment (i.e., when the equipment is turned off). True 152. One way to eliminate setup is to use the same, standardized parts and components for different products. True

Chapter 7 Multiple-Choice 163. Preventive maintenance (PM) is credited in the literature with benefits including which of the following? Improving productivity Improving quality Reducing labor cost *All of the above None of the above 164. Preventive maintenance (PM) is credited in the literature with benefits including which of the following? Increasing inventory turnover

Improving morale Not producing pollution *All of the above None of the above 164. To improve equipment effectiveness (EE) you must minimize equipment losses. Which of the following equipment wastes where identified by Nakajima as the “six big losses”? Idling and minor stoppages Reduced speed of operation Defects caused by variability in equipment performance *All of the above None of the above 164. To improve equipment effectiveness (EE) you must minimize equipment losses. Which of the following equipment wastes where identified by Nakajima as the “six big losses”? Downtime from equipment setup and adjustments Downtime from sporadic or chronic equipment breakdowns Reduced yield caused by a non-optimal operation *All of the above None of the above 165. If the sum of the downtime for equipment repairs is 125 hours and you had a total number of 10 repairs, what is the mean time to repair (MTTR)? 125 50 15 0 *None of the above 165. If the sum of the downtime for equipment repairs is 500 hours and you had a total number of 40 repairs, what is the mean time to repair (MTTR)? 500 40 *12.5 10 None of the above 165. If the sum of the downtime for equipment repairs is 1500 hours and you had a total number of 50 repairs, what is the mean time to repair (MTTR)? 10 20 *30 40 None of the above

165. What is the reliability (i.e., probability in decimal form) that equipment will perform properly under normal operating circumstances if then number of parts (successes with the equipment )is 500 and the number of times the equipment is operated is 1000 in producing the 500 parts? 0.10 0.25 0.30 2.00 *None of the above 165. What is the reliability (i.e., probability in decimal form) that equipment will perform properly under normal operating circumstances if then number of parts (successes with the equipment )is 100 and the number of times the equipment is operated is 125 in producing the 100 parts? 1.00 *0.80 0.50 0.25 None of the above 165. A machine processes 6500 parts of which only 1450 are good. What is the reliability of this machine? About 90% About 80% About 70% About 60% *None of the above is even close 165. A machine processes 1250 parts of which only 875 are good. What is the reliability of this machine? 90% 80% * 70% 60% None of the above is even close 167. If the mean time between failures (MTBF) is high for a collection of processing equipment that can be repaired, which of the following might we infer from that measure? The equipment needs a lot of repair work *The collection of equipment has greater reliability Corrective action needs to be taken in the next day or two Corrective action needs to be taken immediately None of the above 167. If the total running time of a machine is 100 hours and the machine fails...