Lean Management Midterm
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Lean Management Midterm - Leaderboard
Lean Management Midterm - Details
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49 questions
| 🇬🇧 | 🇬🇧 |
| What are the distinctions between JIT, TPS, and Lean ops? | 1. JIT emphasized forced problem solving 2. TPS emphasizes employee learning an empowerment in an assembly line environment 3. Lean ops emphasize understanding the customer |
| Define Lean and provide an example | Lean is a team-based form of continuous improvement focused on identifying and eliminating waste. |
| What are the 3 characteristics of lean? | 1. Eliminate Waste 2. Remove Variability 3. Improve Throughput |
| What are Ohno's 7 wastes? | 1. Overproduction 2. Queues 3. Transportation 4. Inventory 5. Motion 6. Over Processing 7. Defective Products |
| Define Overproduction | Producing more than the customer orders or producing early |
| Define Queues (waste) | Idle time & storage |
| How is Transportation a a waste? | Moving materials between plants or between work centers, handling more than once. |
| What kind of Inventory is a waste? | Unnecessary materials (raw, WIP, finished, ops supplies) |
| How can motion be wasteful? | Movement of equipment or people that adds no value is waste |
| What is over processing (waste)? | Work performed on the product that adds no value. |
| What kinds of Defective products are waste? | Returns, warranty claims, rework, scrap |
| What are the 5 S's? | 1. Sort / Segregate 2. Simplify / Straighten 3. Shine / Sweep 4. Standardize 5. Sustain / Self-discipline |
| What does it mean to Sort/Segregate? | When it doubt, throw it out. |
| What does it mean to Simplify / Straighten? | Keep your station organized and you'll find what you're looking for, |
| What does it mean to Shine/ Sweep? | Keep your station clean |
| Define Standardization | Remove variations through SOPs and checklists |
| Define Sustain/Self-dicipline | Review periodically to recognize efforts and sustain progress. Use visuals for communication. |
| What are the extra 2 S's in the 5s's? | Safety & Support and Maintenence |
| How does an office use the 5s? | A place for everything and everything in its place |
| How do retail stores use the 5S's? | Reduce misplaced items |
| In what ways can variability affect lean operations? | 1. In the production process 2. Maintenance 3.Unknown or changing customer demand 4. Incomplete specs |
| What 2 techniques can be used to identify variability? | JIT & inventory reduction |
| What is throughput? | Measure of what it takes to move an order from start to finish |
| What is a technique for increasing throughput? Give an example | A system Pull system |
| What are the 3 goals of Lean Production? | 1. Elimination of disruptions 2. System Flexibility 3. Continuous Improvement |
| How do disruptions impact lean operations? Give 3 examples of disruptions | Disruptions upset the flow of products through the production system. poor quality, equipment breakdowns, late deliveries. |
| Why is a flexible system important to lean operations? | A flexible system can handle a mix of products and changers to level of output while maintaining throughput speed and enables the system to meet changing demand. |
| What are the principles of Kaizen? | 1. Improvement should be done gradually and continuously 2. Everyone should be involved 3. You don't have to spend on tech and consultants 4. It can be applied anywhere 5. Learn by doing, use scientific thinking 6. Rely on direct observation and data collection |
| What are the 3 Lean Supply Chain Characteristics? | 1. Strict Takt Time 2. Mixed Model Production Schedule 3. Demand Pull over Demand Push |
| What is the formula for Takt Time? | Takt Time = Total work available / Units Required |
| What are the advantages to a Mixed Model Production Schedule? | 1. Minimizes process waste by reducing variation in lead time and demand 2. Similar products are scheduled in groups that have similar design and processes |
| What are 2 characterizations about Demand Pull? | 1. This type of scheduling aligns production capacity to demand patterns 2. Upfront forecasting does not drive the schedule, demand does |
| Are Lean Supply Chain Concepts implementable in every organization? Why or why not? | No because of IT constraints. These systems use MRP or DRP. |
| What are the 4 Critical-To's | Time Cost Quality |
| Define Physical Supply | Goods moving inbound (supplier to manufacturer) |
| Define Physical Distribution | Goods moving outbound (manufacturer to customer) |
| What is a transaction channel? | A channel where you negotiate, sell, and contract. This channel is concerned with transfer of ownership and money. |
| What factors determine how materials move? | 1. Number of channels 2. Types of markets 3. Characteristics of the product 4. Type of transportation available |
| What is reverse logistics? | Supply chain dedicated to the reverse flow of products (returns, repaiirs, remanufacture, recycling) |
| What factors cause reverse logistics? | Quality issues Financial pressures returns of reusable materials Return of packaging |
| What are the 6 Activities in Physical Distribution? | 1. Transportation 2. Distribution Inventory 3. Warehouses 4. Material handling 5. Protective packaging 6. Order processing and communication |
| What are some goals of buyer-supplier partnerships? | 1. Removal of unnecessary activities like receiving, incoming inspection, invoicing, payment 2. Removal of in-plant inventory by delivery of small lots 3. Removal of in-transit inventory by encouraging suppliers to be nearby 4. Long term commitments |
| What are some supplier concerns? | 1. Diversification 2. Scheduling 3. Lead time 4. Quality 5. Lot sizes |
| What are the 3 Characteristics of a Waiting-Line System? Give an example for each | 1. Arrival or inputs to the system: population size, behaviour, stats ditribution 2. The waiting line: limited or unlimited 3. The service facility: design |
| What are the 2 basic Queueing System designs? | 1. Single Channel 2. Multi-Channel |
| What are two ways of standardizing work? | 1. Visual Job Aids 2. Layout |
| What are the results of a good layout? | 1. Higher Utilization of space 2. Improved flow of information, materials, or people 3. Improved Employee morale 4. Improved customer/client interface 5. Flexibility |
| What are 3 Lean analytical tools? Include an example for each | 1. Tools for gathering 1.1 Simple Checksheets 1.2 Scatter Diagrams 1.3 Fishbone Diagrams 2. Tools for organizing 2.1Pareto Charts 2.2 Flowcharts 3. Tools for identifying problems 3.1 5 Why's 3.2 Histograms 3.3 Statistical process control |