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LEAN

Lean manufacturing is a ?

 Means to improve responsiveness to the customer
 Method for reducing labor cost
 Efficiency improvement technique
 Set of tools designed to improve productivity

The 10,000,000,000 dollar spent on material handling equipment has been to a waste of money ?

 True
 False

“Queue” means:

 Material should be pushed to the next operation when a batch is complete
 Waiting
 A unit of measure
 A signal to start production ?

Defective product should be ?

 Displayed for everyone to see
 Scrapped or repaired immediately.
 Moved to the rework process
 Immediately moved to the quality holding area

One-piece-flow means ?

 Batch
 Operators need to work harder
 One piece moves to the next operation
 Larger lot sizes

Products with low demand should be ?

 Batch processed and held in stock until needed
 Assigned higher cost per unit
 Produced in the quantity needed
 Assigned higher cost per unit

Following are the advantages of sticking to the takt time except ?

 It will give you the rhythm in which the system should operate
 Production is smoothly planned and operations will be carried out without interruptions
 Pull scheduling is disabled.
 The system is in synchronization with customer requirement

The main objective of lean manufacturing is to ?

 Outsource much of our manufacturing in order to focus on final assembly
 Produce goods using less resources compared to mass production techniques
 Produce products with fewer options to simplify consumer choices
 Keep labor costs as low as possible by using more of other resources

Lean Thinking should only be implemented when there is no crisis ?

 True
 False

Production line problems should be apparent to even a casual observer ?

 True
 False

Using kanban, production demand is triggered by ?

 Forecast
 Any of the Options
 Removal of product by the downstream customer
 The production planner

Which of the following is not one of the eight wastes ?

 Overproduction
 Transporting
 Excess machine capacity
 Waiting

Kanban is based on a model of ?

 Shipyards
 Job shop machining
 Supermarkets
 Automotive assembly lines

In a lean workcell, the supervisor’s main responsibility is:

 Identifying and resolving abnormal conditions
 Achieving production counts
 Keeping production moving
 Keeping workers busy

In a manufacturing cell, who has authority to stop production?

 Machine operators
 All of the Options
 The material handler
 The line supervisor

Place the 5s's in the proper order ?

 Sort, Set-in-order, Shine, Standardize, Sustain
 Sort, Set-in-order, Shine, Sustain, Standardize
 Sustain, Set-in-order, Shine, Sort, Standardize
 Shine, Sort, Standardize, Set-in-order, Sustain

In a cell, the operators are responsible to ?

 Maximize production output
 Meet customer requirements
 Run the machines or processes assigned
 Direct requests to the supervisor

Mura means ?

 All of the Options
 Doesnt add value
 Overburden and absurdity
 Unevenness (Inconsistency in physical matters)

What do we mean by VSM ?

 Value Stream Mapping
 None of the Options
 Very Serious Mistake
 Valid Sustainable Management

It takes two to three years to complete Lean Manufacturing implementation ?

 True
 False

5S is another word for housekeeping ?

 False
 True

Which of the following is not a goal of lean manufacturing ?

 Reducing set-up times
 Utilizing activity-based costing
 Producing smaller lot sizes
 Increasing machine utilization

We can best increase output by producing parts faster ?

 False
 True

Lean projects should be chosen based on ?

 Anticipated chance for success
 The number of people affected by the changes
 Impact to the customer and to the company
 All of the Options

5S ?

 Relies on the organization and demarcation of the working areas
 A and D
 Targets improvements in morale and efficiency
 Can be done without managerial support
 Is a simple five-step process
 A,C and D