Chapter 07 Lean Thinking and Lean Systems Chapter 7 Lean Thinking and Lean Systems Answer Key Multiple Choice Questions 1 Lean thinking can be applied to A manufacturing B services C functions other than operations D all of the above LO 7 1 Topic Evolution of Lean Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback Lean thinking as a philosophy is applicable across manufacturing and services and outside operations into all aspects of a business 2 Which of the following is NOT an element of lean A Small lot sizes B Modularized master schedule C Multifunction workers D Kanban pull system E Perfect or nearly perfect quality LO 7 2 Topic Lean Tenets Difficulty 1 Easy AACSB Reflective thinking Bloom s Remember Feedback All are true except a modularized master schedule which does not make sense in this context Lean thinking calls for a stabilized master schedule 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 LO 7 4 Topic Controlling Flow with the Kanban System Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback The purpose of the kanban system is to signal the need for more parts just in time to support subsequent work centers 7 1 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 increased utilization of machines LO 7 5 Topic Reducing Setup time and Lot Sizes Difficulty 3 Hard AACSB Reflective thinking Bloom s Understand Feedback Lean thinking does not call for increased machine utilization in fact utilization can decrease in the effort to balance the load across work centers 5 For production control lean pull systems are best suited for A repetitive manufacturing B job shop production C semirepetitive batch manufacturing D unpredictable demand LO 7 4 Topic Controlling Flow with the Kanban System Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback Lean systems work best with stable master schedules a constant takt time and smooth production flow all more likely with a repetitive production situation than the other choices 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 LO 7 6 Topic Suppliers in a Lean System Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback A B and C are all opposite of what lean systems typically require 7 2 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 all of the above LO 7 5 Topic Reducing Setup Time and Lot Sizes Difficulty 1 Easy AACSB Reflective thinking Bloom s Remember Feedback A B and C are all important reasons for decreasing setup time 8 Given the following information pertaining to item AX143 determine the appropriate number of kanban containers that should be used to support production Demand rate 500 units week Time for container to complete circuit 2 weeks Safety stock 30 percent Size of container 5 units A 100 containers B Between 100 and 500 containers C 500 containers D There is not enough information to answer the question LO 7 4 Topic Controlling Flow with the Kanban System Difficulty 2 Moderate AACSB Application of knowledge Bloom s Apply Feedback n DT C 500 x 2 5 200 9 Which of the following is NOT generally an element of a lean system A Flexible workforce B MRP push system C Stable master schedule D Kanban pull system LO 7 2 Topic Lean Tenets Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback An MRP materials requirements planning system is a push system which is philosophically opposed to a lean pull system 7 3 Chapter 07 Lean Thinking and Lean Systems 10 If a work center has no empty kanban containers the workers at the work center should 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 LO 7 4 Topic Controlling Flow with the Kanban System Difficulty 1 Easy AACSB Reflective thinking Bloom s Remember Feedback The purpose of such a physical control system is to stop overproducing if there are no more empty containers to be filled 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 LO 7 5 Topic Reducing Setup time and Lot Sizes Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback The ultimate goal is to eliminate setup time entirely 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 LO 7 5 Topic Reducing Setup time and Lot Sizes Difficulty 2 Moderate AACSB Reflective thinking Bloom s Understand Feedback The ultimate goal is the ability to economically produce just one unit at a time 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 LO 7 4 7 4 Chapter 07 Lean Thinking and Lean Systems Topic Controlling Flow with the Kanban System Difficulty 3 Hard AACSB Reflective thinking Bloom s Understand Feedback Fill wait move use and return time comprise the definition of lead time circuit time 14 If it takes 100 minutes to complete a circuit demand at the next work center is 5 parts per minute and a kanban container holds 20 parts how many containers are required A 25 B 5 C 40 D 20 LO 7 4 Topic Controlling Flow with the Kanban System Difficulty 1 Easy AACSB Application of knowledge Bloom s Apply Feedback n DT C 5 x 100 20 25 15 Managing quality in a lean system A is easy B means that product and service defects are never defined as waste C is done by suppliers D requires continuously exposing and correcting quality problems LO 7 6 Topic Cross Training Rewarding and Engaging Workers Difficulty 2 Moderate AACSB Reflective thinking