Lean Questions and Answers correct

Lean Questions and Answers correct What characteristics best describe Craft Production? (Lean Production Simplified) A workforce comprising quasi-independent tradesmen, Decentralized organization, General-purpose machines, Low production volumes and high prices The authors of both Lean Thinking and Lean Production Simplified demonstrate the applicability of Lean to environments and organizations other than just manufacturing. TRUE To which of the following does the author of Lean Production Simplified attribute what he calls "The Growing Dysfunction" and were problems with the Mass Production system? (Choose ALL that apply) -Poor Quality - high defect rates -Large machinery to take advantage of economies of scale -Worker alienation -Engineering disconnect due to specialization and removal from understanding the "big picture" of design In Lean Production Simplified the author provides two equations for the profit equation: Cost + Profit margin = Price (old equation) and Price (fixed) - Cost = Profit (new equation). He states that the new equation is the new reality because companies can no longer simply take their costs and add profit to it to reach a price but rather they must meet a market price. As a result the key to profitability is cost reduction. TRUE What are examples of the waste of Overprocessing (doing more than the customer requires) (Lean Production Simplified) All of the Above -A mountain bike produced with reflectors and other items riders immediately remove when they get their bike home -15 features in a software package when customers only use 7 of them -Sanding a locker door smoother than required by the specifications -Having a quality inspection after every toaster oven has been produced although no defects or variations had been noted in several months What characteristics best describe The Ford System? (Lean Production Simplified) Interchangeability and ease of assembly of parts, Reduction of actions required by each worker, Moving assembly line Specifying Value (Lean Principle #1) is from the perspective of the company designing and producing the product or service. (Lean Thinking) FALSE In Lean Thinking the author uses the travel from the UK to Greece as an example of Value from the perspective of the customer who is travelling and encompasses the entire Value Stream which includes multiple companies and processes. TRUE The Eight forms of Waste (Muda) are: (Lean Production Simplified) Motion, Delay, Conveyance, Correction, Overprocessing, Inventory, Overproduction, Knowledge Disconnection What characteristics best describe Mass Production? (Lean Production Simplified) Standardized work, reduced cycle time, time and motion study, measurement and analysis to continually improve the process Taylorism is a term often synonymous with mindless and dehumanizing work and the pioneers of lean production such as Taiichi Ohno and Shigeo Shingo completely shun Taylor's work. (Lean Production Simplified) FALSE Specifying Value (Lean Principle #1) is not just for manufacturing but also for services and other non-manufacturing processes. (Lean Thinking) TRUE From Lean Production Simplified, what are the Foundation, Walls, Roof, and Heart of the Lean System Stability, Standardization, Just-In-Time, Jidoka, Customer Focus, Involvement A central goal of the Lean System is to eliminate Waste (Muda) so as to improve profitability (Both Texts) TRUE Taiichi Ohno thought that people were expendable and had little to offer the company. (Lean Production Simplified) FALSE Muda or Waste is partly the idea of only that which adds value in the eyes of the customer and everything else is Waste or non-Value Added. Which of the following is NOT a category of Human Motion. (Lean Production Simplified) Unless a human is moving they are lazy Overproduction can cause other wastes; one of the reasons it is considered the most serious waste. (Lean Production Simplified) TRUE Just because an operation, step, or situation occurs that does not add value to the product or service does not mean it is Waste (Muda), legal requirements or steps due to outdated technology, for example. (Lean Production Simplified) FALSE Mura refers to unevenness or fluctuation in work, usually caused by fluctuating production plans. What is NOT an example of Mura Zero fluctuations in work from shift to shift In the section of the book Lean Production Simplified titled "A Virtue of Necessity" the author points out that Toyota and Ohno discovered the benefits of producing smaller batches of product and quick changeover from one product to another. Which of the following are benefits he attributes to smaller batches and quick changeover? -Reduced lead times -Cost saving -Quality Some Guidelines for Tools and Jigs include: All items n this list - Jig design to avoid manual holding of materials - Use ergonomic tools - Combine tools where possible - Use balancers that automatically take away the tool where possible A job element sheet shows all the operations in a job where a job element is the minimum action or group of actions required to advance a process. TRUE Because we want overall efficiency in a process (and in a system) and not isolate, individual efficiency we either need to or may need to do the following: All of the above -Have cycle times as balanced as possible -Make sure areas of responsibility overlap -Have distances between workers as short as possible -We may need to have inventory or other buffers between processes because different processes are not balanced It would be a good idea for companies to have a small group of affected employees work on TPM activities. (Lean Production Simplified) True The author contends that we have four (4) inputs we have to manage in our organization's system. These include which of the following? -Manpower (Man/Woman - People) -Materials -Method -Machine In Lean Production Simplified the author states that improvement is impossible without stability in the 4M's. Which of the following are included in the 4M's: All of the above -Manpower (Man/Woman - People) -Materials -Method -Machine Throughput is the amount of product that can be moved through a system in a certain amount of time. A system is comprised of a series of dependent processes and each is subject to statistical fluctuations or variation. Eli Goldratt showed two challenges: Variables like inventory down the line will fluctuate around the maximum deviation (variability) established by upstream processes and Throughput is governed by the slowest process in the chain (the bottleneck). According to Goldratt we have to do which of the following: - Identify our bottlenecks - Decide how to exploit our bottlenecks - Elevate the bottleneck (make improving it the most important thing) What are some Guidelines for Layout and Equipment? - Identify home positions for tools and materials - Build flexibility into the layout to accommodate demand changes and taller or shorter operators - Move parts horizontally and avoid vertical part movements and use gravity to move parts - Place tools and materials conveniently - Ensure adequate lighting - Use colors - Use U-shaped layouts so that process start and end points are side by side According to the author most companies track OEE and have better than 90% OEE. (Lean Production Simplified) FALSE In Lean Production Simplified the author says that occasionally they had to take non-lean action such as increasing buffers, or adding people or equipment to buy time until root causes to problems were found and solved True In a Production Capacity Chart we use the equation Capacity = Operational time per shift / (Process time + setup time). If we have an 8.5 hour shift with a total of 45 minutes for breaks (465 minutes total available per shift) and a process time of 36.6 seconds per unit (including actual process time plus setup time) for a process what is our capacity for that process for the entire shift? 762.3 units per shift Stability starts with visual management and the 5S system (Lean Production Simplified) TRUE The author contends that we have six (6) outputs we have to manage in our organization's system. These include which of the following? - Productivity - Quality - Cost - Delivery time - Safety and environment - Morale The Lean Improvement Process includes which of the following: (Lean Production Simplified) - Stabilize the 4M's - Flow - Pull - Improve the system Which of the following represent the Maintenance Stages, in typical order of how a firm progresses? (Lean Production Simplified) Breakdown maintenance (firefighting), Preventive maintenance (some proactive planning and troubleshooting), TPM=(Preventive + Predictive Maintenance) + Total Involvement Match the appropriate Lean Thinking vs. Methods Engineering concepts. - Standards change (and only the experts can change them) - Methods engineering - Not only do experts know better but once you have the single best method you should stick to it and change it only after the experts find the time to study it and improve upon it - Workers should design the work - Leaning thinking - workers know.... - Workers are not involved in designing the work or making improvements - Methods engineering - engin..... - There is a single best way (and the engineers will find it) - Methods engineering - assumption about whether a standard should or should not change - There is no one best way to do the work - Leaning thinking - Even the best.... - The purpose of standardized work is to provide a basis for improvement - Leaning thinking - Mura is une.... Standards can flexible in that workers can choose to follow them or not depending on whether or not they think they have a better method. (Lean Production Simplified) FALSE Cycle time is the actual time to perform a process whereas takt time is how frequently we must produce a product. Our goal is to synchronize takt time with cycle time to the greatest extent possible TRUE The author says he came to understand at Toyota (about standards and standardized work) that: - There is no one best way to do the work - Workers should design the work - The purpose of standardized work is to provide a basis for improvement - The best processes are rife with muda and therefore standardized work constantly changes In the equation for efficiency, Efficiency = Output / Manpower, the only way to improve efficiency is to get the customer to order product more evenly FALSE Cycle time is the actual time to perform a process whereas takt time is how frequently we must produce a product. Our goal is to synchronize takt time with cycle time to the greatest extent possible TRUE