Answer at the bottom of the page
Chapter 7
Lean Thinking and Lean Systems
Multiple Choice Questions
1. Lean thinking can be applied to:
A. Manufacturing
B. Services
C. Functions other than operations
D. All of the above
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
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
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
5. For production control, lean pull systems are best suited for:
A. Repetitive manufacturing
B. Job shop production
C. Semi-repetitive batch manufacturing
D. Unpredictable demand
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
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
8. Given the following information pertaining to an item, determine the appropriate number of kanban cards 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 units
B. Between 100 and 500 units
C. >500 units
D. There is not enough information to answer the question
9. Which of the following is NOT generally an element of a lean system?
A. Flexible workforce
B. Type II MRP system
C. Stable master schedule
D. Kanban pull system
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
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
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
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
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
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
16. Supplier management in a lean system:
A. May require co-location of supplier goods close to plants that receive delivery
B. Means and increase in the number of suppliers for each component
C. Generally involves short-term relationships with the buyer
D. Usually requires additional paperwork, as compared with the non-lean system
17. One of the main objectives of a lean system is:
A. Striving for ‘good enough’
B. Reduction of takt time
C. Reduction of waste
D. Define value from the manufacturer’s perspective
18. Why is a uniform load desirable in a lean system?
A. To balance the workload on all work centers
B. To allow for production of safety stock
C. To signal the need for more parts
D. To increase the time for scheduled maintenance
19. Reduction of setup time is accomplished by separating internal and external setups and:
A. Reducing inventory
B. Implementing a kanban system
C. Converting internal setup time to external setup time
D. Reducing lot sizes
20. External setup time refers to:
A. The time it takes workers to set up a machine during scheduled maintenance
B. The time to complete setup activities that do not require that the machine be stopped
C. The time it takes equipment vendors to set up the machine
D. None of the above
True / False Questions
21. External setups refer to actions that require stoppage of the production process.
True False
22. According to the lean philosophy, a stable master production schedule is desirable to reduce the work-in-process inventories.
True False
23. Value stream maps are similar to flowcharts and are used for identifying the waste and non-value-added steps in the current process.
True False
24. Lean is an example of a pull system while lean thinking is an example of a push system.
True False
25. A kanban system cannot be used in service industries.
True False
26. Kaizen events typically take between 1 to 2 months.
True False
27. One-touch setups could require as long as 9 minutes to perform.
True False
28. With lean thinking, a firm’s operations layout should evolve to a cellular manufacturing layout.
True False
29. One of the keys to reducing inventory is reducing lead-time.
True False
30. Preventive maintenance is another term for stabilizing the master schedule.
True False
31. Takt time is the available time for production divided by demand.
True False
32. Toyota Production System is another term for a lean system.
True False
33. “Gemba” refers to data collection using the company’s information system.
True False
34. The Japanese term for waste is “gemba.”
True False
Essay Questions
35. What are the five tenets of lean thinking? In your own words, provide a road map for implementing lean thinking in a manufacturing or service operations.
36. What are the seven forms of waste associated with a lean system?
37. Explain the concept of value stream mapping.
38. How is the 5 Whys technique used in a lean system?
39. Define the English terms in the 5S technique. How is this applied in practice?