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Exam 8: Lean Systems

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Question 41

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A ________ is a workstation in which a worker operates several different machines simultaneously to achieve a line flow.

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one-worker...

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Question 42

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In a lean system,large inventories are not considered a type of waste,because they prevent operator wait times.

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Question 43

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Case 8.1 The Edward James Toy Company uses a Kanban system to make plastic wheels that are a component of several toys.The waiting time for a container of the wheels during production is 0.25 day;average processing time is 0.15 day per container.Each container holds 200 wheels.The company uses 2000 wheels a day in the production of its products. -Use the information in Case 8.1.Using a policy variable of 5%,calculate the number of Kanban containers needed for the wheels.

A five S program includes the activities of "simplify" and "system."

Lean systems use the standardization of components because standardization:

________ refers to a form of supplier partnership that places a supplier representative,who is empowered to plan and schedule the replenishment of materials from the supplier,in the customer's plant on a full-time basis.

A takt time of 90 seconds generates a process output of:

Just-in-time (JIT)systems need close relationships with suppliers.

The Peeps factory can be described as a three step process consisting of Mixing,Forming,and Packaging.Peeps are made in batches of 1000 and have a daily demand of 75,000 units during what the plant manager likes to call "the Peep season." Mixing has a cycle time of .02 seconds with a setup time of 30 seconds;Forming has a setup time of 24 seconds and a cycle time of .03 seconds,and Packaging has a setup time of 15 seconds with a cycle time of .04 seconds.Each process step is handled by one operator,who is available for 8 hours a day.What is the process bottleneck if each process step is assumed to have 100% uptime?

A ________ is based on both a withdrawal card and a production-order card,to control inventory quantities more closely.

Champion Cooling Company uses a kanban system at their location in the Oklahoma City Metroplex.The daily demand for fans is 2000 and management insists on using an alpha level of 0.1.They use containers that hold 20 items and takes 0.04 of a day to process.It takes 0.07 of a day to get a container filled and for it to wait during its cycle.How many containers should they use? If they use the nearest integer value number of containers,what is the actual system alpha?

What is the difference between the "push" and "pull" methods of material flow? Which method does lean systems use?

Regarding the Eight Types of Waste that must be eliminated to implement lean systems,excessive movement and material handling of product between processes is part of which general waste category?

The value stream mapping tool often requires completion of the future state drawing before the current state drawing,to help managers see the future state goals and more easily identify problems with the current state of the process.

In a lean system,wait times can be caused to some extent by long production runs.

A one-person cell in which a worker operates several different machines simultaneously to achieve a line flow is called a one-worker,multiple-machines (OWMM)cell.

Lean systems try to:

The Japanese practice of andon means that production does not begin until a card or bin is empty.

In the Toyota Production System,when a work station needs more material,it is obvious to both the worker and the supplier that material is needed.Further,the amount needed must be understood as well as the delivery time for replenishment.

Which one of the following statements is best?