Test 17 October 2013, questions and answers PDF

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Operational management chapter 7 test ...

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Operations Management: Processes and Supply Chains, 10e (Krajewski et al.) Chapter 8 Lean Systems 1) The just-in-time (JIT) philosophy is the belief that cutting inventory and removing non-value-added activities in operations can eliminate waste. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: JIT, just-in-time, value added, inventory, non-value-added Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 2) Kaizen is the Japanese term for continuous improvement. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: lean systems, inventory, types of waste 3) In a lean system, large inventories are not considered a type of waste, because they prevent operator wait times. Answer: FALSE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: lean systems, wait times, types of waste 4) In a lean system, wait times can be caused to some extent by long production runs. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: lean systems, wait times, types of waste 5) Manufacturing an item before it is needed in a lean system is not considered waste, because it helps keep material flowing through the system. Answer: FALSE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: lean systems, types of waste, overproduction 6) In service systems, a common approach used to stress the system and identify problems is to reduce the number of employees doing an activity until the process begins to slow or come to a halt. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: lean systems, service systems, value added

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7) In manufacturing systems, one way to achieve continuous improvement can be to maintain low inventories, and periodically cut safety stocks almost to zero. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: lean systems, manufacturing systems, value added 8) Just-in-time (JIT) systems need close relationships with suppliers. Answer: TRUE Reference: Supply Chain Considerations in Lean Systems Difficulty: Moderate Keywords: JIT, just-in-time, supplier relationship Learning Outcome: Compare common approaches to supply chain design. 9) If infrequent, large shipments of purchased items are arranged with suppliers, large inventory savings for these items can be realized. Answer: FALSE Reference: Supply Chain Considerations in Lean Systems Difficulty: Moderate Keywords: shipments, inventory, savings, suppliers Learning Outcome: Compare common approaches to supply chain design. 10) JIT II refers to a form of supplier partnership that places a supplier representative, who is empowered to plan and schedule the replenishment of materials from the supplier, in the customer's plant on a fulltime basis. Answer: TRUE Reference: Supply Chain Considerations in Lean Systems Difficulty: Moderate Keywords: JIT II, supplier partnership, supplier in-plant representative Learning Outcome: Compare common approaches to supply chain design. 11) The goal of single-digit setup is to have a setup completed in fewer than 10 hours. Answer: FALSE Reference: Supply Chain Considerations in Lean Systems Difficulty: Moderate Keywords: single-digit setup 12) In lean systems, the need for single-digit setups is driven by the desire for small lot sizes. Answer: TRUE Reference: Supply Chain Considerations in Lean Systems Difficulty: Moderate Keywords: lean systems, small lot sizes, single-digit setup

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13) In a lean system, excess inventory hides problems on the shop floor, and thus prevents sources of waste from being identified and eliminated. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: lean systems, types of waste, inventory 14) While overproduction creates an item before it is needed, the extra time before an item is needed makes it easier to detect defects and reduce their impact on a process. Answer: FALSE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: lean systems, types of waste, inventory, defects 15) In lean systems, work-in-process inventory is a direct result of overproduction and waiting. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: lean systems, types of waste, inventory, overproduction, waiting 16) Using expensive, high precision equipment, even when simpler machines would suffice, is encouraged when lean systems are implemented, because this is the only way high quality manufacturing can be achieved. Answer: FALSE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: lean systems, types of waste, inappropriate processing, defects 17) Long production runs, poor material flows, and processes that are not tightly linked to one another can cause over 90% of a product's lead time to be spent waiting. Answer: TRUE Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: lean systems, types of waste, long production runs, material flow, overproduction, waiting 18) The push method begins the production of items in advance of customer needs. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Easy Keywords: push production 19) Push systems are often used in firms with highly repetitive processes and well defined work flows of standardized items. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: push production, repetitive processes, defined work flows, standardized items

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20) The pull method begins the production of an item in advance of customer needs. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Easy Keywords: pull production 21) Firms that have highly repetitive processes and well-defined work flows of standardized items often use the pull method. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: pull production, repetitive processes, defined work flows, standardized items 22) Just-in-time (JIT) systems rely on inspectors to inspect quality into the product. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Easy Keywords: JIT, just-in-time, quality 23) Quality at the source is a philosophy whereby defects are caught and corrected where they are created. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Easy Keywords: lean systems, quality at the source 24) Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called heijunka. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: heijunka 25) Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called jidoka. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: jidoka 26) A power cord that can be plugged in only one way is an example of a poka-yoke. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: JIT, just-in-time, quality, poka-yoke

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27) The Japanese practice of andon means that production does not begin until a card or bin is empty. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: andon, card, bin 28) Takt time is the cycle time needed to match the rate of production to the rate of sales. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: takt time 29) Takt time is the cycle time needed to maximize utilization of an organization's workers and equipment. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: takt time 30) A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 90 seconds. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: takt time AACSB: Analytic skills 31) A firm that averages sales of 320 units for every 480-minute shift it runs has a takt time of 40 seconds. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: takt time AACSB: Analytic skills 32) Heijunka is the leveling of production load by both volume and product mix. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: heijunka 33) Mixed-model assembly is a type of assembly that produces a mix of models in smaller lots. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: mixed model assembly, small lot size

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34) Productivity tends to increase when components are standardized because each worker performs a standardized task or work method more often each day. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: productivity, standardized components, standardized work method 35) A five S program includes the activities of "simplify" and "system." Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Easy Keywords: 5S, five S, JIT, just-in-time 36) Five S practices can enable workers to visually see everything differently, prioritize tasks, and achieve a greater degree of focus. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: 5S, five S 37) Five S practices can be applied to both manufacturing and service settings and can include offices, work spaces, tool rooms, and shop floors. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: 5S, five S 38) Preventive maintenance is typically given very low priority in just-in-time systems. Answer: FALSE Reference: Process Consideration in Lean Systems Difficulty: Easy Keywords: preventive maintenance, JIT, just-in-time 39) One tactic of Total Preventive Maintenance (TPM) is to make workers responsible for routine minor maintenance of their own equipment. Answer: TRUE Reference: Process Consideration in Lean Systems Difficulty: Moderate Keywords: Total Preventive Maintenance (TPM) 40) Lean systems are operating systems that maximize the value added of each of its activities by paring unnecessary resources and delays from them. Answer: TRUE Reference: Toyota Production System Difficulty: Easy Keywords: lean systems, value added Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 6 Copyright © 2013 Pearson Education, Inc. publishing as Prentice Hall

41) While lean systems work very well for manufacturing systems, they cannot be applied to service systems. Answer: FALSE Reference: Toyota Production System Difficulty: Easy Keywords: lean systems, manufacturing systems, service systems Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 42) One benefit of a lean system is that it reduces space requirements. Answer: TRUE Reference: Designing Lean System Layouts Difficulty: Moderate Keywords: just-in-time, JIT, space requirements, lean system Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 43) Options for achieving line-flow layouts in a lean system include assigning one worker to operate several different machines in a line and creating cells to produce similar product groups called families. Answer: TRUE Reference: Designing Lean System Layouts Difficulty: Moderate Keywords: just-in-time, JIT, one-worker, multiple-machine, OWMM, group technology, GT 44) A one-person cell in which a worker operates several different machines simultaneously to achieve a line flow is called a one-worker, multiple-machines (OWMM) cell. Answer: TRUE Reference: Designing Lean System Layouts Difficulty: Moderate Keywords: line flow, one-worker, multiple-machine, OWMM 45) An OWMM arrangement reduces labor requirements but increases inventory. Answer: FALSE Reference: Designing Lean System Layouts Difficulty: Moderate Keywords: line flow, one-worker, multiple-machine, OWMM, labor requirements, inventory 46) Group technology collects similar parts into families and organizes machine tools into separate cells. Answer: TRUE Reference: Designing Lean System Layouts Difficulty: Moderate Keywords: group technology, GT, machine tools, cells, parts families

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47) A Kanban is a card used to control the flow of production in many just-in-time systems. Answer: TRUE Reference: The Kanban System Difficulty: Easy Keywords: Kanban card 48) In a Kanban system, materials may be withdrawn without a withdrawal card if the operation requiring the material is about to run out of work. Answer: FALSE Reference: The Kanban System Difficulty: Moderate Keywords: Kanban system, Kanban card 49) Some Kanban systems are set up without Kanban cards, and use the material containers or open spaces in a work area to withdraw materials. Answer: TRUE Reference: The Kanban System Difficulty: Moderate Keywords: Kanban system, container system, containerless system 50) As the average processing time per container of parts increases, fewer containers are needed in a Kanban system. Answer: FALSE Reference: The Kanban System Difficulty: Moderate Keywords: Kanban system 51) Use of value stream mapping requires construction of a current state drawing, a future state drawing, and an implementation plan. Answer: TRUE Reference: Value Stream Mapping Difficulty: Easy Keywords: value stream mapping, current state drawing, future state drawing, implementation plan 52) The value stream mapping tool often requires completion of the future state drawing before the current state drawing, to help managers see the future state goals and more easily identify problems with the current state of the process. Answer: FALSE Reference: Value Stream Mapping Difficulty: Moderate Keywords: value stream mapping, current state drawing, future state drawing

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53) To complete the current state drawing of a process, a map of the current situation is developed, including such items as material and information flows, process times, setup times, batch sizes, scrap rates, and number of people required. Answer: TRUE Reference: Value Stream Mapping Difficulty: Moderate Keywords: value stream mapping, current state drawing, material and information flows 54) Often in value stream mapping, analysts must rely on process information from shop floor workers rather than direct observation in an effort to quickly develop a work plan and accelerate implementing the improved process. Answer: FALSE Reference: Value Stream Mapping Difficulty: Moderate Keywords: value stream mapping, process information, direct observation 55) The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints, while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities. Answer: TRUE Reference: Value Stream Mapping Difficulty: Moderate Keywords: theory of constraints, value stream mapping Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 56) A value stream map shows the flows of materials and information and the lines of responsibility and authority. Answer: FALSE Reference: Value Stream Mapping Difficulty: Moderate Keywords: value stream mapping, material flow, information flow 57) After the earthquake and tsunami of 2011, Toyota's suppliers and plants were able to maintain production levels due to their efficiency. Answer: FALSE Reference: Toyota Production System Difficulty: Easy Keywords: Toyota production system, earthquake 58) Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving. Answer: FALSE Reference: Toyota Production System Difficulty: Easy Keywords: Toyota production system, scientific method

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59) In the Toyota Production System, when a work station needs more material, it is obvious to both the worker and the supplier that material is needed. Further, the amount needed must be understood as well as the delivery time for replenishment. Answer: TRUE Reference: Toyota Production System Difficulty: Easy Keywords: TPS, Toyota production system, customer-supplier connection 60) The Toyota Production System requires that any process improvements are to be made at the lowest level of the organization. Answer: TRUE Reference: Toyota Production System Difficulty: Easy Keywords: Toyota production system, scientific method 61) In the Toyota Production System, services and goods flow to the next available person or machine to maintain smooth, rapid flow. Answer: FALSE Reference: Toyota Production System Difficulty: Moderate Keywords: Toyota production system, pathway 62) One big advantage of lean systems is that they can usually be put in place without any major changes to existing layouts. Answer: FALSE Reference: Operational Benefits and Implementation Issues Difficulty: Easy Keywords: lean system, line-flow layout Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 63) Lean systems do not need stable master production schedules. Answer: FALSE Reference: Operational Benefits and Implementation Issues Difficulty: Easy Keywords: JIT, just in time, master schedule, lean system Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma

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64) Lean systems try to: A) produce a product in anticipation of demand. B) maximize the value added by of each of its activities. C) organize production in large lots to minimize the number of setups. D) reduce the labor content in all processes. Answer: B Reference: Toyota Production System Difficulty: Moderate Keywords: lean system, value added Learning Outcome: Describe the advantages and disadvantage of various production strategies such as lean, Theory of Constraints, JIT, and Six-Sigma 65) The just-in-time (JIT) system is a(n): A) management system of people and procedures to fulfill all delivery deadlines. B) production system of small-lot manufacturing to reduce work-in-process inventory. C) materials management system for removing all inventories. D) integrated system of managing resources, information, and decision processes to eliminate waste. Answer: D Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Moderate Keywords: JIT, just-in-time, integrated system, waste elimination 66) Regarding the Eight Types of Waste that must be eliminated to implement lean systems, excessive movement and material handling of product between processes is part of which general waste category? A) Motion B) Transportation C) Inappropriate Processing D) Underutilization of Employees Answer: B Reference: Continuous Improvement Using a Lean Systems Approach Difficulty: Easy Keywords: types of waste, transportation ...