Chapter 14

Question 1

A ____ is a flexible system of operations that uses fewer resources than traditional systems

Answer 1

Lean operation

Question 2

What are Just-in-time (JIT) systems?

Answer 2

Highly coordinated processing system in which goods move through the system just as they are needed

Question 3

What does it mean for Lean operations to eliminate waste?

Answer 3

Eliminate non-value adding activities

Question 4

What are two hallmarks of lean systems?

Answer 4

• Waste Reduction
• Continuous Improvement

Question 5

What are the five principles of lean operations?

Answer 5

1) Identify customer values
2) Focus on value-adding processes/activities
3) Eliminate waste
4) Produce only according to demand
5) Strive for perfection

Question 6

What are 3 risks of lean operations?

Answer 6

1) Increased stress for workers
2) Fewer resources available
3) Supply chain disruptions can result in shutdowns

Question 7

____ has served as a model for many implementations of lean systems, particularly in manufacturing

Answer 7

Toyota Production System (TPS)

Question 8

What does Muda refer to?

Answer 8

Waste and inefficiency

Question 9

What is a manual system used for signaling the need of parts and materials?

Answer 9

Kanban

Question 10

What does Heijunka refer to?

Answer 10

Workload leveling

Question 11

Variations in production volume lead to _____

Answer 11

Waste

Question 12

What does Kaizen mean?

Answer 12

Continuous improvement of a system

Question 13

What does Jidoka mean?

Answer 13

Quality at the source

Question 14

What is autonomation?

Answer 14

When a machine automatically stops when it detects a bad part; a worker then stops the line

Question 15

What is the ultimate goal of a lean operation?

Answer 15

Is to achieve a system that matches supply to customer demand; supply is synchronized to meet customer demand (balance)

Question 16

What are the 3 supporting goals of a Lean system?

Answer 16

1) Eliminate disruptions
2) Make the system flexible
3) Eliminate waste - excess inventory

Question 17

___ have a negative influence on the system by upsetting the smooth flow of production

Answer 17

Disruptions

Question 18

____ is one that is robust enough to handle a mix of products and changes of output while maintaining balance

Answer 18

Flexible systems

Question 19

What are the 8 wastes (muda)

Answer 19

1) Excess inventory
2) Overproduction
3) Waiting time
4) Unnecessary transporting
5) Processing waste
6) Inefficient methods
7 Product defects
8) Underused people

Question 20

What are the 4 building blocks of lean systems?

Answer 20

1) Product design
2) Process design
3) Personnel/organizational elements
4) Manufacturing planning/control

Question 21

What are the 4 elements of product design important for a lean system?

Answer 21

1) Standard parts
2) Modular design
3) Highly capable production systems with quality built in
4) Concurrent engineering

Question 22

What two elements relate to speed and simplicity?

Answer 22

1) Standard parts
2) Modular design

Question 23

Is it better for lean systems to have smaller or larger lot sizes in the process?

Answer 23

Smaller

Question 24

Quality is the _____ of lean

Answer 24

Sine qua non (Without which not)

Question 25

____ is a system for reducing changeover time

Answer 25

Single-minute exchange of die (SMED)

Question 26

Under SMED systems, what is an internal activity?

Answer 26

Those that can only be done while a machine is stopped Contribute to long changeover times

Question 27

Under SMED systems, what are external activities?

Answer 27

Those that do not involve stopping the machine; can be done before/after the changeover

Question 28

______ contain the machines and tools needed to process families of parts having similar processing requirements

Answer 28

Manufacturing cells

Question 29

____ often focuses on the finding and eliminating the causes of problems so they do not continually pop up

Answer 29

Quality Improvement

Question 30

What are 6 ways to improve production flexibility?

Answer 30

1) Reduce downtime due to changeovers 2) Preventative maintenance 3) Cross-train workers 4) Use many small units of capacity 5) Use offline buffers 6) Reserve capacity for important customers

Question 31

___ is the cycle time needed in a production system to match the pace of production to the demand rate

Answer 31

Takt Time

Question 32

Using Takt time results in _____.

Answer 32

Minimizing WIP inventory in instances where demand is stable and system capacity matches demand

Question 33

What is the primary risk of low inventory?

Answer 33

No safety net

Question 34

What does Poka-yoke refer to?

Answer 34

Safeguards built into a process to reduce the possibility of errors; "Mistake proofing"

Question 35

What are the 5 elements of personnel important to Lean Systems?

Answer 35

1) Workers as assets 2) Cross-trained workers 3) Continuous improvement 4) Cost accounting 5) Leadership/project management

Question 36

What is a system of lights used at each workstation to signal problems or slowdowns?

Answer 36

Andon

Question 37

Method designed to more closely reflect the actual amount of overhead consumed by a particular job

Answer 37

Activity-based costing

Question 38

Lean encourages ____ between workers and managers

Answer 38

Two-way communication

Question 39

What is a benefit of a buffer supply in production?