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WorksheetsLean Manufacturing
Total questions: 32
Worksheet time: 16mins
Which of the following statements combine to form a valid definition of lean manufacturing? Lean manufacturing…
is a rigidly defined set of steps to follow.
focuses on reducing waste.
is a set of tools and philosophies.
focuses on automation of production.
Which of the following are stressed by the principal of scientific management?
Management must ensure that each task is always performed in the best way.
There is always a best way of performing a particular task.
Every unit of a part that is produced must be identical.
Automation must be implemented wherever possible.
Of the following, which is usually the easiest to control?
Transportation costs
Raw material costs
Production costs
Design costs
In which of the following ways can a machine not outperform a human worker?
Reliability
Speed
Flexibility
Endurance
The chronological order of innovations in manufacturing is:
Mechanization and MRP, interchangeable parts, scientific management
Interchangeable parts, scientific management, mechanization and MRP.
interchangeable parts, scientific management
Scientific management, mechanization and MRP, interchangeable parts
The Seven Wastes are all examples of:
Overburden (muri)
Inconsistency (mura)
Wasted work (muda)
Which of the following wastes occur as a result of overproduction?
Insurance costs are higher.
More space is required to store excess product.
Handling and management costs are increased.
Large quantities of parts can be made obsolete simultaneously.
The basic formula of business is Profit = Sales – Expenses. Lean manufacturing aims to:
Reduce expenses
Increase sales
Balance sales and expenses
Increase expenses
A particular machine can only work at 70% of its maximum speed due to its age. Because of frequent repairs, the machine cannot be used for 10% of each shift. The machine produces many faulty parts – approximately 5% of all pars produced are scrapped. What is the overall equipment effective value of this machine?
59.85%
3.1%
70%
3.5%
An example of the implementation of a sequence poka-yoke method is:
A pre-counted back of screws
A warning sign placed on a door
A warning light that shines when a mistake is made
An activation switch that cannot be pressed until a safety door is closed
An example of the implementation of the contact method is:
a pre-counted packs of screws.
an asymmetrically shaped connector.
A large sign warning of potential danger.
Which of the following statements is true of Pull systems?
Pull systems create more finished product than is required.
Pull systems lengthen production times.
Pull systems ensure that the factory only produces what is needed.
Pull systems are being phased out in favor of push systems.
Kanban sizes must be set accurately using special formulae. Adjustments to the sizes set by formulae can only harm the system.
True
False
One piece flow is another name for the concept of batch production.
True
False
The takt time is calculated as:
Minutes per shift x Shifts per day / Units required per day
Minutes per shift x Shifts per day x Units required per day
Minutes per shift / (Shifts per day x Units required per day)
Which of the following are part of Just-In-Time (JIT) manufacturing?
Steady flow and one piece flow
Pull manufacturing and steady flow
One piece flow, pull manufacturing and steady flow
One piece flow and pull manufacturing
The concept of leveling production means:
Ensuring that the same quantity of product is produced each day
Ensuring that production levels match customer demand levels
Ensuring that all steps in a production process work at a compatible rate
Ensuring that all production batch sizes are as small as possible
Value stream mapping means:
Sketching how a factory runs.
Calculating the value of a factory against its costs.
Drawing a map of a factory, highlighting the most value increasing areas.
A simple shoe factory is required to produce 200 pairs of shoes per five hour shift. If there is only one person responsible for threading the laces, how long should it take that person to thread the lace of one shoe?
1 minute
3 minutes
0.75 minutes
1.5 minutes
TAKT time can be defined as:
The time interval between which finished goods should exit the factory.
The maximum time any operation in the factory can take.
The maximum time that unfinished parts can wait between manufacturing steps.
The time that each operation in the factory should take.
Listed below are some of the steps to be followed when redesigning a manufacturing process. Which is the correct chronological order?
Level production, Calculate the efficiency of the revised process, Identify and solve obvious wastes at each workstation, Calculate the TAKT time and measure cycle times.
Identify and solve obvious wastes at each workstation, Calculate the TAKT time and measure cycle times, Level production, Calculate the efficiency of the revised process
Calculate the TAKT time and measure cycle times, Level production, Calculate the efficiency of the revised process, Identify and solve obvious wastes at each workstation
Which of the following is not shown in a value stream map?
How long each manufacturing process takes per part
How information passes through the factory
How the machines are set out physically in the factory
Buffer stock between processes
A computer assembly plant assembles 1000 computers per hour. Deliveries of computer power supplies can be made every twenty minutes. What kanban size should be set for power supplies? (Each computer requires one power supply.)
At least 1000
At least 334
At least 111
At least 3000
The word Kanban means:
Station
Card
Factory
Unit
The size of kanban bins for work in progress are calculated in the same way as for raw material kanbans.
true
false
An advantage of using kanban systems is that the factory is forced to work according to a pull scheduling system.
True
False
Appreciation analysis is mainly used to understand the implications of a problem, more than to define the root of the problem.
False
True
Pareto analysis is based on the concept that almost all causes of a particular problem have similar levels of impact.
True
False
In order to successfully solve any problem, which is the correct order of the steps that should be followed?
1 Identify possible solutions.
2 Evaluate and select the best solution.
3 Implement the solution.
4 Define the problem.
1 Evaluate and select the best solution.
2 Implement the solution.
3 Define the problem.
4 Identify possible solutions.
1 Define the problem.
2 Identify possible solutions.
3 Evaluate and select the best solution.
4 Implement the solution.
1 Implement the solution.
2 Define the problem.
3 Identify possible solutions.
4 Evaluate and select the best solution.
In appreciation analysis, which question is asked repeatedly?
When?
Why?
How?
So what?
The main problem with decision matrix analysis is that:
The calculations become complex when many criteria are considered.
The method is only relevant when comparing a small number of alternatives.
The criteria weightings and the scores assigned almost always require subjective decision making.
One requires a lot of training in order to be able to perform the analysis.
Which technique is used to test a theory that a particular factor might be causing a specific problem?
The 5 Whys
Scatter diagrams
Brainstorming
The Appreciation technique
