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| 1 | |
Reported benefits of lean implementations include all of the following except: |
| | A) | reduced inventory levels |
| | B) | reduced manufacturing lead times |
| | C) | improved product quality |
| | D) | smaller storage requirements |
| | E) | increased product development times |
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| 2 | |
Which of the following statements regarding lean systems is false? |
| | A) | Lean is a philosophy that emphasizes continuous improvement. |
| | B) | Lean is an approach that seeks to have the right item, at the right place, at the right time, in the right quality, and the right quantity. |
| | C) | In a lean system, waste is any activity that does not add value. |
| | D) | As a management philosophy, lean is not applicable to low-volume manufacturing or service operations. |
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| 3 | |
Suzaki identified the "seven wastes," which include all of the following except: |
| | A) | overproduction |
| | B) | waiting time |
| | C) | defects |
| | D) | inventory |
| | E) | reengineering |
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| 4 | |
Which of the following statements regarding lean systems is false? |
| | A) | In general, lean is a push-type of production planning system. |
| | B) | Lean systems emphasize reduction in setup (changeover) times. |
| | C) | Lean factories emphasize the simplification of production processes. |
| | D) | Lean systems emphasize reduction in inventory levels. |
| | E) | Lean systems utilize "kanbans" to signal the need for production. |
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| 5 | |
Common elements of a lean approach to production include all of the following except: |
| | A) | small lot sizes |
| | B) | limiting inventory to the maximum amount that the number of containers used in the system may hold |
| | C) | an emphasis on quick changeovers |
| | D) | production schedules that are highly variable from period to period |
| | E) | use of multifunction workers |
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| 6 | |
In a lean system, work-in-process inventory is: |
| | A) | increased to prevent stoppages due to production problems |
| | B) | ignored because it has little effect on the availability of finished goods inventory |
| | C) | reduced to reveal production problems, which can then be solved |
| | D) | eliminated completely |
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| 7 | |
Inventory hides a variety of forms of waste. Which of the following is not an example of waste hidden by inventory? |
| | A) | inferior product quality |
| | B) | unreliable machines |
| | C) | long, but certain, delivery lead times |
| | D) | long setup times |
| | E) | unreliable vendors |
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| 8 | |
Lean programs emphasize all of the following except: |
| | A) | using teamwork concepts to help improve product quality |
| | B) | increasing worker productivity by removing the quality control responsibility from workers and placing this responsibility in independent quality control inspection departments |
| | C) | providing quality control training for all employees |
| | D) | providing an environment that recognizes the importance of continuous improvement |
| | E) | developing and improving internal and external customer/supplier relationships |
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| 9 | |
Which one of the following is not an element of lean thinking? |
| | A) | value stream mapping |
| | B) | specifying value from the customer's point of view |
| | C) | matching supply to demand |
| | D) | striving for perfection |
| | E) | a very flexible short-term master schedule |
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| 10 | |
Given the following information pertaining to item X123, determine the appropriate number of kanbans that should be used to support production.
Usage (demand) = 140units/week
Lead Time = 1 week
Safety Stock = 25 percent
Container size = 2 units |
| | A) | 70 units |
| | B) | 140 units |
| | C) | 87.5 units |
| | D) | 140.125 units |
| | E) | 175 units |
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| 11 | |
Which of the following statements is incorrect about the lean thinking approach? |
| | A) | The lean thinking approach can be extended beyond the production process to the finance, marketing and accounting functions. |
| | B) | The lean thinking approach was popularized by Womack and Jones. |
| | C) | The lean thinking approach can be easily applied to service operations. |
| | D) | The lean thinking approach takes an internal perspective of the firm starting with the production process. |
| | E) | none of the above |
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| 12 | |
Lean systems require sophisticated control systems to manage the workflow at the shop-floor level. |
| | A) | TRUE |
| | B) | FALSE |
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| 13 | |
Lean systems emphasize limiting the number of suppliers to improve a company’s relationships with its suppliers. |
| | A) | TRUE |
| | B) | FALSE |
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| 14 | |
According to the lean philosophy, it is important to rely on incoming inspection to reduce the generation of waste in a production process. |
| | A) | TRUE |
| | B) | FALSE |
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| 15 | |
Matching supply to demand is called cycle time. |
| | A) | TRUE |
| | B) | FALSE |
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| 16 | |
The objective of lean is to improve ROI. |
| | A) | TRUE |
| | B) | FALSE |
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| 17 | |
Internal setup requires that a machine be stopped. |
| | A) | TRUE |
| | B) | FALSE |
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| 18 | |
Lean implementation should start with the final assembly line. |
| | A) | TRUE |
| | B) | FALSE |
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| 19 | |
A Kaizen event is a long-term continuous improvement project. |
| | A) | TRUE |
| | B) | FALSE |
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