Lean Midterm Questions With Complete Solutions
'A' items use what type of line design Correct Answers
dedicated lines
'B' items use what type of line design Correct Answers shared
lines- linear, U-form
'C' items use what type of line design Correct Answers
departments or job shops
2 poka-yoke categories Correct Answers 1. control poka-yoke:
worker alerted, line stopped
2. warning poka-yoke: worker alerted only
3 control poka-yoke methods Correct Answers 1. contact
method
- detect abnormalities in work piece size, shape, orientation,
position, etc
2. altogether method
- ensures that all steps of an operation have been successfully
completed
3. action step method
- worker takes some action which is not part of the normal
operations routine
3 improvement avenues in lean Correct Answers 5S
standardization
TPM
,4 approaches to detecting the problem and stopping the process
in Jidoka Correct Answers 1. line stops on manual production
lines
2. poka-yoke devices
3. mistake-proofing devices
4. autonomous machines
4 basic setup time reduction concepts Correct Answers 1.
separate the internal setup from the external setup
2. convert as much as possible of the internal setup to the
external setup
3. eliminate the adjustment process
4. abolish the setup itself
4 kinds of muda in manufacturing Correct Answers excessive
production resources (workforce, facilities)
overproduction
excessive inventories
unnecessary capital investment
6 basic setup time reduction techniques Correct Answers 1.
standardize the external setup actions
2. standardize only the necessary portions of the machine
3. quick fasteners
4. use supplementary tooling
5. use parallel operations
6. use a mechanical setup systems
a high variance and skewed distribution results in Correct
Answers max daily inventories
difficulty for part suppliers
, difficulty in running the line
all units inspection Correct Answers lot (batch) production
using automated equipment
- first and last unit of each lot are inspected, so if both are good
then the entire lot is considered to be good
alternative configurations to having batch production with
individual machines Correct Answers 1. conveyors or chutes
- close distances
- MG and buffer
- BUT it encourages WIP and isolates the workers
2. Full-work control
- close distances
- controls WIP
3. single buffer
- close distances
4. separate input/ output buffers
- farther distances
Andon and call lights Correct Answers call light: light on
means supervisor, maintenance worker, or general worker is
needed
andon: board providing information on state of line
autonomous machines Correct Answers machine with an
automatic stopping device
IMPORTANT IN LEAN BECAUSE they made multi-process
handling and all units inspection possible
'A' items use what type of line design Correct Answers
dedicated lines
'B' items use what type of line design Correct Answers shared
lines- linear, U-form
'C' items use what type of line design Correct Answers
departments or job shops
2 poka-yoke categories Correct Answers 1. control poka-yoke:
worker alerted, line stopped
2. warning poka-yoke: worker alerted only
3 control poka-yoke methods Correct Answers 1. contact
method
- detect abnormalities in work piece size, shape, orientation,
position, etc
2. altogether method
- ensures that all steps of an operation have been successfully
completed
3. action step method
- worker takes some action which is not part of the normal
operations routine
3 improvement avenues in lean Correct Answers 5S
standardization
TPM
,4 approaches to detecting the problem and stopping the process
in Jidoka Correct Answers 1. line stops on manual production
lines
2. poka-yoke devices
3. mistake-proofing devices
4. autonomous machines
4 basic setup time reduction concepts Correct Answers 1.
separate the internal setup from the external setup
2. convert as much as possible of the internal setup to the
external setup
3. eliminate the adjustment process
4. abolish the setup itself
4 kinds of muda in manufacturing Correct Answers excessive
production resources (workforce, facilities)
overproduction
excessive inventories
unnecessary capital investment
6 basic setup time reduction techniques Correct Answers 1.
standardize the external setup actions
2. standardize only the necessary portions of the machine
3. quick fasteners
4. use supplementary tooling
5. use parallel operations
6. use a mechanical setup systems
a high variance and skewed distribution results in Correct
Answers max daily inventories
difficulty for part suppliers
, difficulty in running the line
all units inspection Correct Answers lot (batch) production
using automated equipment
- first and last unit of each lot are inspected, so if both are good
then the entire lot is considered to be good
alternative configurations to having batch production with
individual machines Correct Answers 1. conveyors or chutes
- close distances
- MG and buffer
- BUT it encourages WIP and isolates the workers
2. Full-work control
- close distances
- controls WIP
3. single buffer
- close distances
4. separate input/ output buffers
- farther distances
Andon and call lights Correct Answers call light: light on
means supervisor, maintenance worker, or general worker is
needed
andon: board providing information on state of line
autonomous machines Correct Answers machine with an
automatic stopping device
IMPORTANT IN LEAN BECAUSE they made multi-process
handling and all units inspection possible
