Chapter 16

Question 1

a focus on continuous improvement

Answer 1

kaizen

Question 2

members of a work cell or team meet to develop improvements in the process

Answer 2

kaizen event

Question 3

any activity that does not add value in the eyes of the customer

Answer 3

waste

Question 4

is any deviation from the optimum process that delivers perfect product on time, every time

Answer 4

variability

Question 5

: the rate at which units move through a production process

Answer 5

Throughput:

Question 6

___is the war on waste

Answer 6

lean

Question 7

the japanese word for waste

Answer 7

muda

Question 8

: producing more than the customer orders or producing early

Answer 8

Overproduction:

Question 9

: idle time, storage and waiting

Answer 9

Queues:

Question 10

moving material between plants or between work centers

Answer 10

transportation

Question 11

unnecessary raw material, WIP, finished goods and excess operating supplies

Answer 11

inventory

Question 12

: movement of equipment or people that adds no value

Answer 12

motions

Question 13

work performed on the product that adds no value

Answer 13

overprocessing

Question 14

returns, warranty claims, rework and scrap

Answer 14

Defective Products:

Question 15

Lean systems require managers to reduce variability caused by

Answer 15

both internal and external factors

Question 16

the time between the arrival of raw materials and the shipping of the finished order
A “pull” system increases throughput

Answer 16

Manufacturing cycle time:

Question 17

produces finished goods inventory in advance of customer demand using a forecast of sales

Answer 17

Push system:

Question 18

employees at a given operation (work station) go to the source of the required parts, such as machining or subassembly, and withdraw the units as they need them

Answer 18

Pull system:

Question 19

: the process of producing large quantities of items as a group before being transferred to the next operation

Answer 19

batching

Question 20

the concept of ideally using batch sizes of one

Answer 20

Single-piece flow

Question 21

To utilize single-piece flow, a company must be able to ________ quickly and inexpensively by reducing setup times

Answer 21

To utilize single-piece flow, a company must be able to change between products quickly and inexpensively by reducing setup times

Question 22

the Japanese word for card, which has come to mean “signal”

moves parts through production via a “pull” from a signal

Answer 22

kanban

Question 23

: indicators for operating activities that are placed in plain sight of all employees so that everyone can quickly and easily understand the status and performance of the work system

Answer 23

visual controls

Question 24

refers to quick setup or changeover of tooling and fixtures in processes so that multiple products in smaller batches can be run on the same equipment

Answer 24

Single Minute Exchange of Dies (SMED)

Question 25

activities that can only be done while machine is stopped

Answer 25

Internal:

Question 26

activities that do not require stopping the machine

Answer 26

external

Question 27

ensuring that operating systems will perform their intended function reliably

Answer 27

Total Productive Maintenance (TPM):

Question 28

The 5S principles are as follows:

Answer 28

sort, straighten, shine, standardize, sustain

Question 29

US Managers often add two additional S’s

Answer 29

safety and support/maintenance