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Exam 6: Lean Systems

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Question 1

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List and briefly define the 5S Practices that serve as an enabler and essential foundation of lean systems.

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Question 2

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________ refers to mistake-proofing methods aimed at designing fail-safe systems that minimize human error.

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The theory of constraints accepts existing system bottlenecks and works to maximize throughput given these constraints, while value stream mapping endeavors to understand how existing processes can be altered to eliminate bottlenecks and other wasteful activities.

Toyota sets up all of its operations as experiments and teaches employees at all levels how to use the trial and error method of problem solving.

Lean systems maintain inventory in small lot sizes because small lot sizes:

In the Toyota Production System, all work must be completely specified as to ________, ________, ________ and ________.

Mistake-proofing is known by the term:

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.

Scenario 6.1 El Gran Raton, the producers of the finest carpincho wallets in all of Argentina, examined their production process in the form of a value stream map, displayed below. Daniel Penfield artist -With a batch size of 360 units, which process step in Scenario 6.1 is the bottleneck?

With respect to lean systems, what is the advantage of standardized components?

Which of the following actions would increase the number of containers in use in a Kanban system?

A plant's manufacturing process has a takt time of 90 seconds per unit. This results in a process output of how many units per hour?

An item sells at a rate of 600 units per day. If a plant works two shifts per day (480 minutes each shift), what takt time is required for the plant to meet this demand?

Using customer demand to activate production of an item or service is called:

Use of value stream mapping requires construction of a current state drawing, a future state drawing, and an implementation plan.

Choose a simple, common process and create a value stream map containing the current state, plus a realistic future state, and implementation plan.

Champion Cooling Company uses a kanban system at their location in the Oklahoma City Metroplex. The daily demand for fans is 2,000 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?

List and briefly define the eight types of waste (or muda) that often occur in firms which must be eliminated in implementing lean systems.

Case 6.1 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 2,000 wheels a day in the production of its products. -Use the information in Case 6.1. Using a policy variable of 5%, calculate the number of Kanban containers needed for the wheels.

What are the supply chain implications of the lean system emphasis on close supplier ties?