Chapter 16

Question 1

supply the customer with exactly what the customer wants when the customer wants it, without waste, through continuous improvement.

Answer 1

lean operations

Question 2

focuses on continuous forced problem solving.

Answer 2

just-in-time (JIT)

Question 3

emphasizes continuous improvement, respect for people, and standard work practices

Answer 3

Toyota Production System (TPS)

Question 4

three fundamental issues with lean operations:

Answer 4

eliminate waste, remove variability, and improve throughout

Question 5

___ is anything that does not add value from the customer point of view

Answer 5

waste

Question 6

Ohno's Seven Wastes:
-overproduction
\_\_\_\_\_
\_\_\_\_\_\_
-inventory
-motion
-overprocessing
\_\_\_ \_\_\_\_\_

Answer 6

queues, transportation, defective products

Question 7

The 5S's:
-sort/segregate
-simplify/straighten
-shine/sweep
\_\_\_\_\_
\_\_\_/\_\_\_\_\_\_

Answer 7

standardize, sustain/self-discipline

Question 8

two additional S’s:

Answer 8

safety and support/maintenance

Question 9

any deviation from the optimum process

Answer 9

variability

Question 10

lean systems require managers to reduce variability caused by

Answer 10

internal and external factors

Question 11

Sources of variability:

• poor processes resulting improper quantities, late, or non-conforming units
• inadequate maintenance
• unknown and changing customer demands
• ___ or ___ drawings, specifications or bills of material.

Answer 11

incomplete or inaccurate

Question 12

time between arrival of raw materials and the shipping of the finished order

Answer 12

manufacturing cycle time

Question 13

increases throughput

Answer 13

pull system

Question 14

exists when a supplier and purchaser work together to remove waste and drive down costs

Answer 14

supplier partnership

Question 15

four goals of supplier partnerships are:

• removal of unnecessary ___
• removal of ____ _____
• removal of in-transit inventory
• improved quality and ____

Answer 15

activities, in-plant inventory, reliability

Question 16

___ ____ reduces waste due to movement.

Answer 16

lean layout

Question 17

large lots and long production lines with single purpose machinery are being replaced by smaller flexible cells. often u-shaped for shorter paths and improved communication. often using group technology concepts

Answer 17

distance reduction

Question 18

cells designed to be rearranged as volume or designs change. applicable in office environments as well as production settings. facilitates both product and process improvement.

Answer 18

increased flexibility

Question 19

inventory is at the minimum level necessary to keep operations running.

Answer 19

lean inventory

Question 20

reducing inventory uncovers the ___ and problems are exposed.

Answer 20

“rocks”

Question 21

Shingo says “________”

Answer 21

inventory is evil

Question 22

ideal situation is to have lot sizes of one pulled from one process to the next. often not feasible.

Answer 22

reduce lot sizes

Question 23

schedules must be communicated inside and outside the organization.

Answer 23

lean scheduling

Question 24

process frequent small batches, may depend upon market demand.

Answer 24

level schedules

Question 25

Japanese word for card. authorization for the next container of material to be produced. many different sorts of signals are used but system is still called this

Answer 25

Kanban

Question 26

lean exposes poor ___

Answer 26

quality

Question 27

because lead times are shorter, quality problems are ___ ____. better quality means fewer buffers and allows simpler lean systems to be used.

Answer 27

exposed sooner.

Question 28

TPS uses continuous improvement, builds an organizational culture and value system that stresses improvement of all processes called

Answer 28

kaizen

Question 29

TPS word for stopping production because of a defect

Answer 29

jidoka

Question 30

lean ___ understands the customer and their expectations.

Answer 30

organizations

Question 31

lean systems tend to have the following attributes:

• respect and develop employees
• empower employees
• develop worker flexibility
• develop collaborative partnerships with suppliers
• eliminate waste

Answer 31

yay

Question 32

maximize resource use and economic efficiency. focus on issues outside the immediate firm. driving out waste is the common ground

Answer 32

lean sustainibility

Question 33

Lean techniques used in manufacturing are used in services. these are: acronoym for it is SLIS

Answer 33

suppliers, layouts, inventory and scheduling.