Chapter 07 - Lean Thinking and Lean SystemsChapter 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: 7.1Topic: Evolution of LeanDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: 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 sizesB. Modularized master scheduleC. Multifunction workersD. Kanban pull systemE. Perfect or nearly perfect qualityLO: 7.2Topic: Lean TenetsDifficulty: 1 EasyAACSB: Reflective thinkingBloom’s: RememberFeedback: 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: 7.4Topic: Controlling Flow with the Kanban SystemDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: The purpose of the kanban system is to signal the need for more parts just in time to support subsequent work centers. 7-1Chapter 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: 7.5Topic: Reducing Setup time and Lot SizesDifficulty: 3 HardAACSB: Reflective thinkingBloom’s: UnderstandFeedback: 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: 7.4Topic: Controlling Flow with the Kanban SystemDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: 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: 7.6Topic: Suppliers in a Lean SystemDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: A, B, and C are all opposite of what lean systems typically require.7-2Chapter 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: 7.5Topic: Reducing Setup Time and Lot SizesDifficulty: 1 EasyAACSB: Reflective thinkingBloom’s: RememberFeedback: 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: 7.4Topic: Controlling Flow with the Kanban SystemDifficulty: 2 ModerateAACSB: Application of knowledgeBloom’s: ApplyFeedback: n = (DT)/C = (500 x 2)/5 = 2009. Which of the following is NOT generally an element of a lean system? A. Flexible workforceB. MRP push systemC. Stable master scheduleD. Kanban pull systemLO: 7.2Topic: Lean TenetsDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: An MRP (materials requirements planning) system is a push system, which is philosophically opposed to a lean pull system. 7-3Chapter 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: 7.4Topic: Controlling Flow with the Kanban SystemDifficulty: 1 EasyAACSB: Reflective thinkingBloom’s: RememberFeedback: 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: 7.5Topic: Reducing Setup time and Lot SizesDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: 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: 7.5Topic: Reducing Setup time and Lot SizesDifficulty: 2 ModerateAACSB: Reflective thinkingBloom’s: UnderstandFeedback: 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: 7.47-4Chapter 07 - Lean Thinking and Lean SystemsTopic: Controlling Flow with the Kanban SystemDifficulty: 3 HardAACSB: Reflective thinkingBloom’s: UnderstandFeedback: 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. 25B. 5C. 40D. 20LO: 7.4Topic: Controlling Flow with the Kanban SystemDifficulty: 1 EasyAACSB: Application of knowledgeBloom’s: ApplyFeedback: 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