6) Consider the adjacent work stations in this two card kanban system. There is a move card located:
A) in box A.
B) in box B.
C) both in box A and box C.
D) in box C.
7) Consider the adjacent work stations in this two card kanban system. There is a production card
located:
A) in box A.
B) in box B.
C) at work center 1 and work center 2.
D) in box C.
8) Consider the adjacent work stations in this two card kanban system. There is a production card located
in the box labeled Outgoing Parts B. Work Center 3 pulls the parts from Work Center 2. Where does the
production card go?
A) The production card remains in the same box.
B) The production card is placed at Work Center 3.
C) The production card is placed at Work Center 2.
D) The production card is placed in the box labeled Incoming Parts A.
9) Consider the adjacent work stations in this two card kanban system. Work Center 3 has just pulled the
Incoming Parts C box to their work station. What happens to the cards in the Incoming Parts C box and at
the work station?
A) The move card at their station goes in the Incoming Parts C box and the production card is pulled
from the Incoming Parts C box to signal the worker at Work Center 2 that there is a need to produce
material.
B) The production card at the station is passed back to Work Center 2 as a signal to produce more
material and the move card is left at Work Center 3 to signal that they are ready to accept materials when
they are complete at Work Center 2.
C) The move card at their station goes in the box they will send downstream to Work Center 4 and the
production card is placed at the Work Center 3 station while they are working on this batch of material.
D) The production card at their station goes in the Incoming Parts C box and the move card is pulled
from the Incoming Parts C box to signal the worker at Work Center 2 that there is a need to move
material.
10) Consider the adjacent work stations in this two card kanban system. Work Center 3 has just pulled the
Incoming Parts C box to their work station. Which of these statements is best?
A) The move card will move backward from Work Center 3 to Work Center 2.
B) The production card will move backward from Work Center 3 to Work Center 2.
C) The move card will move forward from Work Center 3 to Work Center 4.
D) Despite its name, the move card doesn’t actually move from one station to the next, it will simply
reside at Work Center 3 until the next box is finished.
11) Consider the adjacent work stations in this two card kanban system. Work Center 3 has just pulled the
Incoming Parts C box to their work station. Plant manager Taichi Ohno grabs the microphone for the
company PA system and announces that effective immediately, the company will switch to a one card
system. Which of these actions is appropriate?
A) The production card will be discarded and the empty container will function as a production signal.
B) The production card will be discarded and the empty container will function as a move signal.
C) Both the move and production cards will be discarded in favor of a combined move/production card.
D) The production card will be discarded as production will be implied and the move cards will signal
when items are needed downstream.
12) Which of the following statements regarding supply chain synchronization using kanbans is BEST?
A) An interruption in the flow of goods within a supplier‘s assembly operations will have no effect on
final assembly downstream in the supply chain.
B) For the system to work properly, demand rates must be relatively stable and interruptions must be
minimized.
C) If final assembly demand doubles, there is no need to change kanbans at each of the suppliers.
D) Final assembly demand may rise or fall, but the sum of the kanbans among all suppliers in the supply
chain will remain constant.
13) Liversuch Industries uses a kanban system to manage production of the J-15 subassembly. They have
an hourly demand for 250 units and use containers that can hold 50 units each. It takes 90 minutes to fill
and move a container of parts to the right place on the J-15 line that is currently rated at a 20% safety
factor. How many production cards are needed?
A) 540
B) 100
C) 9
D) 1.5
14) Livermore Industries uses a kanban system to manage production of the KR-9 subassembly. In a ten–
hour day, they use 1500 units and use containers that can hold 50 units each. It takes 45 minutes to fill
and move a container of parts to the right place on the KR-9 line that is currently rated at a 15% safety
factor. How many production cards are needed?
A) 3
B) 26
C) 82
D) 155
15) Livernonions Industries uses a kanban system to manage production of the BR–549 subassembly. In
an eight-hour day, they use 900 units and use containers that can hold 30 units each. It takes 120 minutes
to fill and move a container of parts to the right place on the BR-549 line that is currently rated at a 15%
safety factor. How many production hours of inventory are needed?
A) 18.4
B) 7.6
C) 4.3
D) 2.4
16) Two announcers are used to read names at the semiannual commencement exercises held at a
regional university in America’s heartland. All students have their names read then walk briskly to the
president who shakes their hand and offers them an empty diploma cover until such time that all
financial obligations to the university have been met. The president greets about 640 students in an eight–
hour day. The diploma covers come in boxes of 24 and it takes one hour to carry one from the receiving
dock to the field house where the ceremony is held. The president likes to keep things moving, so he has
requested a 50% safety factor. How many containers are needed?
A) two
B) three
C) four
D) five
17) Two announcers are used to read names at the semiannual commencement exercises held at a
regional university in America’s heartland. All students have their names read then walk briskly to the
president who shakes their hand and offers them an empty diploma cover until such time that all
financial obligations to the university have been met. The president greets about 900 students in an eight–
hour day. The diploma covers come in boxes of 12 and it takes one hour to carry one from the receiving
dock to the field house where the ceremony is held. The president likes to keep things moving, so he has
requested a 50% safety factor. How many containers are needed?
A) 14
B) 13
C) 12
D) 1
18) When using MRP and kanban together:
A) the control capabilities of MRP are used instead of those from kanban.
B) the planning capabilities of kanban are used instead of those from MRP.
C) the demand rate should be variable in order to derive the greatest benefit from the MRP portion of the
system.
D) this information is used to recalculate the number of production kanbans needed.
19) A two-card kanban system is a planning tool that links production and movement of units at only two
work centers.
20) The cards employed in a two-card kanban system are the production card and the move card.
21) A pull system is a production system in which actual downstream demand sets off a chain of events
that pull material through various steps in the various process steps.
22) The forecast for next month is 200 units so the manufacturer gathers materials for this anticipated
level of production activity. This is an example of a pull system.
23) For a kanban system to work properly, demand rates must be relatively stable, and interruptions
must be minimized or quickly resolved.
24) Some companies have found it beneficial to combine the planning capabilities of kanban with the
control capabilities of MRP.
25) The greater the demand, the more kanbans are needed.
26) An increase in the safety factor results in an increase in the amount of inventory in a kanban system.
27) In the kanban formula, the letter T represents the time it takes to empty a box of parts through
building product.
28) A(n) ________ is a production control approach that uses containers, cards, or visual cues to control
production and movement of goods throughout the supply chain.
29) Under two-card kanban system rules, each box of raw material must have a(n) ________, while each
box of finished goods must have a(n) ________.
30) A manufacturer waits to produce until they have an order from a customer. This type of production
system is called ________.
31) The number of kanbans in a production system is inversely related to the ________.
32) Companies that use MRP and kanban together use the ________ of MRP and the ________ of kanban.
33) Describe the movements of parts and kanbans in a two-card kanban system.
34) What are the consequences of unstable demand and interrupted flows on a supply chain managed
with a Lean philosophy?
35) Two modules are used to feed the final assembly station on an assembly line. The final assembly
station must produce 250 units in an eight-hour day. Each finished unit needs two module A’s and 3
module B’s. The factory uses a standard sized container that can hold 25 module A’s or 35 module B’s. It
takes 2 hours to fill and move a container of module A’s, but only 90 minutes to fill and move a container
of module B’s. If both module assembly processes have safety factors of 15%, how many containers
should be used for each? How many hours of demand will this satisfy?
36) Two announcers are used to read names at the semiannual commencement exercises held at a
regional university in America’s heartland. All students have their names read then walk briskly to the
president who shakes their hand and offers them an empty diploma cover until such time that all
financial obligations to the university have been met. The president greets about 600 students in an eight–
hour day. The diploma covers come in boxes of 24 and it takes 45 minutes to carry one from the receiving
dock to the field house where the ceremony is held. The president likes to keep things moving, so he has
requested a 50% safety factor. How many containers are needed?
37) Use this material requirements planning record to explain how kanbans and MRP can be used
together. This plant operates on a 40-hour week, and uses a 10% safety factor on a container size of 20
units with a half-day turnaround time on a container. What features of each system should be used and
for what purposes?
Week
1
2
3
Gross Requirement
900
1000
1100
Scheduled Receipts
0
0
0
Projected Ending Inventory
0
0
0
Net Requirements
900
1000
1100
Planned Receipts
900
1000
1100
Planned Orders
900
1000
1100