Chapter 10

Question 1

Which of the following is NOT associated with lean production?

Answer 1

Increased holding costs.

Question 2

Lean management regards excess inventory as:

Answer 2

waste.

Question 3

Which of the following is a TRUE statement about lean management?

Answer 3

Lean is management philosophy.

Question 4

External setups:

Answer 4

can be done while the machine is running.

Question 5

Which of the following would you NOT expect to see in a lean manufacturing plant?

Answer 5

Waste.

Question 6

Which of the following lean concepts can be applied to service environments?

Answer 6

Total visibility
Flexibility
Holistic approach
Continuous improvement

Question 7

Which of the following is consistent with a lean perspective on set up times reduction?

Answer 7

Make as much setup as possible external.

Question 8

Lean high quality depends on

Answer 8

each worker being his own inspector

Question 9

Synchronization and balance refers to:

Answer 9

reduction of bottlenecks

Question 10

A kanban system is based on:

Answer 10

a manual card sytem

Question 11

In a lean system, preventive maintenance is:

Answer 11

the responsibility of machine operators.

Question 12

What is the term that means giving workers authority to top the production line when quality problems are encountered?

Answer 12

Jidoka

Question 13

The original system for eliminating waste in processes is known as:

Answer 13

the Toyota Production System.

Question 14

The philosophy of JIT

Answer 14

originated in Japan

Question 15

In a restraunt, synchronization and balance is

Answer 15

a requirement

Question 16

A focused factory is one that:

Answer 16

is small and tends to specialize.

Question 17

Group technology includes grouping

Answer 17

machines by product.

Question 18

Some excess capacity in a lean system

Answer 18

is not considered to be a serious problem.

Question 19

If it is desired to reduce the amount of inventory in the system, the number of Kanban cards should

Answer 19

be decreased.

Question 20

In a lean system, quality is

Answer 20

built in, not inspected in.

Question 21

Which of the following lean concepts as identified by Duclos, Siha, and Lummus can be applied to service environments?

Answer 21

Synchronization and balance of information and workflow
Flexibility in the use of resources
Holistic approach to waste elimination
Continuous improvement of the process

Question 22

Which of the following lean concepts is NOT applicable to service environments?

Answer 22

Well defined work rules defining specific authority for labor.

Question 23

Which of the seven deadly wastes involves workers who are idle?

Answer 23

Waiting time.

Question 24

Labor planning:

Answer 24

A means of determining staffing policies dealing with employment stability, work schedules, and work rules.

Question 25

Job enlargement:

Answer 25

The grouping of a variety of tasks about the same skill level, horizontal enlargement.

Question 26

Job rotation:

Answer 26

a system in which an employee is moved from one specialized job to another.

Question 27

Job enrichment:

Answer 27

a method of giving an employee more responsibility that inludes some of the planning and control necessary for job accomplishment; vertical expansion.

Question 28

employee empowerment:

Answer 28

enlarging employee jobs so that the added responsibility and authority are moved to the lowest level possible.

Question 29

job design:

Answer 29

an approach that specifies the tasks that constitute a job for an individual or a group

Question 30

Labor specialization (job specialization)

Answer 30

the division of labor into unique "special" tasks

Question 31

self-directed team:

Answer 31

a group of empowered individuals working together to reach a common goal.

Question 32

ergonomics:

Answer 32

the study of the human interface with the environment and machines

Question 33

Methods analysis:

Answer 33

a system hat involves developing work procedures that are safe and produce quality products efficiently.

Question 34

Flow diagram:

Answer 34

A drawing used to analyze movement of people or material

Question 35

Process chart:

Answer 35

Graphic representations that depict a sequence of steps for a process.

Question 36

Activity chart:

Answer 36

a way of improving utilization of an operator and a machine or some combination of operators (a crew) and machines.

Question 37

operations chart:

Answer 37

a chart depicting right and left hand motions.

Question 38

visual workplace:

Answer 38

uses a variety of visual communication techniques to rapidly communicate information to stakeholders

Question 39

labor standards:

Answer 39

the amount of time required to perform a job or part of a job

Question 40

time study:

Answer 40

timing a sample of a worker's performance and using it as a basis for setting a standard time.

Question 41

average observed time:

Answer 41

the arithmetic mean of the times for each element measured, adjusted for unusual influence for each element.

Question 42

Normal time:

Answer 42

the average observed time, adjusted for pace.

Question 43

Standard time:

Answer 43

an adjustment to the tota normal time; the adjustment provides allowances for personal needs, unavoidable work delays and fatigue.

Question 44

predetermined time standards:

Answer 44

a division of manual work into small basic elements that have established and widely accepted times.

Question 45

therblig:

Answer 45

basic physical elements of motion.

Question 46

Time measurement units (TMUs)

Answer 46

units for very basic micromotions in which 1 TMU = .0006 min, or 100,000 TMUs - 1 HR.

Question 47

work sampling:

Answer 47

an estimate, via sampling, of the percentage of the time that a worker spends on various tasks.

Question 48

When product demand fluctuates and yet you maintain a constant level of employment, some of your cost savings might include:

Answer 48

1. reduction in hiring costs 2. reduction in layoff costs and unemployment insurance costs 3. lack of need to pay a premium wage to get workers to accept unstable employment 4. having a trained workforce rather than having to retrain new employees each time you hire for an upswing in demand

Question 49

The difference between job enrichment and job enlargement is that:

Answer 49

enlarged jobs contain a larger number of similar tasks, while enriched jobs include some of the planning and control necessary for job accomplishment.

Question 50

The work environment includes these factors:

Answer 50

Lighting Noise Temperature Air quality

Question 51

Methods analysis focuses on:

Answer 51

how a task is accomplished.

Question 52

The least preferred method of establishing labor standards is:

Answer 52

historical experience.

Question 53

The allowance factor in a time study:

Answer 53

adjusts normal time for personal needs, unavoidable delays, and fatigue.

Question 54

To set the required sample size in a time study, you must know:

Answer 54

the desired accuracy and confidence levels.

Question 55

Inspection in a lean plant is:

Answer 55

done by machines whenever possible.