Continuous Flow

Question 1

a Lean method that allows you to move a single product through every step of your process instead of grouping work items into batches

Answer 1

Continuous Flow

Question 2

erms One piece flow Value Stream and perspective of the customer Value Added, Business Added Eliminate everything else (waste) Work in Place Inventory (WIP)

Question 3

Working on one produce at a time (or batch size of one)

Answer 3

Single Piece Flow

Question 4

Creating a group of items before moving the group to the next step in production.

Answer 4

Batching

Question 5

An escalator is an example of _____.
a.) Single Piece Flow
b.) Batching

Answer 5

a.) Single Piece Flow

Question 6

An elevator is an example of _____.
a.) Single Piece Flow
b.) Batching

Answer 6

b.) Batching

Question 7

Documents requiring leadership approval are collected and reviewed once each day/week is an example of _____.
a.) Single Piece Flow
b.) Batching

Answer 7

b.) Batching

Question 8

Documents requiring leadership approval are reviewed as they arrive is an example of _____.
a.) Single Piece Flow
b.) Batching

Answer 8

a.) Single Piece Flow

Question 9

What are some effects of decreasing batch size?

Answer 9

Increase response to the customer
Reduce waiting (time in queue)
Decrease lead time
Reduce dependency on forecasting
Reduce inventory
Enhance flow

Question 10

Below describes a Push System or a Pull System?
*Based on forecasts or schedules
*Disregards subsequent process steps
High inventoryPoor communication
*Anticipates usage
*Waste (large lots, inventory)
*Propagates errors

Answer 10

Push System

Question 11

Below describes a Push System or a Pull System?
*Response to customer demand
*Pulls from previous operations
*Just in time
*Good communication
*Actual consumption
*Small lots
*Reduces errors

Answer 11

Pull System

Question 12

What are some aspects of a Pull System?

Answer 12

1) Are flexible and simple
2) Include triggers for work to be done
3) Link work cells together
4) Are executed automatically

Question 13

M_____ + M_____ = M_____

Answer 13

Maps + Measures = Metrics

Question 14

Universal Metric that can be used in any value stream…
Processing Time ÷ Lead Time

Answer 14

Process Cycle Efficiency (PCE)

Question 15

Throughput = WIP / cycle time

Answer 15

Little’s Law

Question 16

A unit or a machine that uses the highest percentageof its full capacity, or is fully utilized, can create a bottleneck in the process

Answer 16

Full Capacity Utilization

Question 17

Earliest step where WIP inventory gathers

Answer 17

Bottleneck

Question 18

Low WIP inventory gathering

Answer 18

Continuous Flow

Question 19

Kanban, Yamazumi, and Swim lanes are tools to identify what?

Answer 19

A bottleneck

Question 20

in Japanese means “to stack up”; line-balancing

Answer 20

Yamazumi

Question 21

Where can you find the bottleneck of a process?
a)​The first process step
b)The process step that takes the longest
c)The process step with the most inventory
d)The first process step exceeding Takt Time

Answer 21

d)The first process step exceeding Takt Time

Question 22

Which term most closely describes a “bottleneck”?
a)​Inventory
b)Defect
c)Constraint
d)Jidoka

Answer 22

c) Constraint

Question 23

Various tools could be used in order to identify the Bottleneck of a process. Which of the following is most appropriate?
a)​Spaghetti Diagram
b)Yamazumior Line Balancing Diagram
c)Time and motion studies (measured observations of workers activities)
d)Instant observations (on a representative sample) of the operational statistics of a workstation

Answer 23

b) Yamazumior Line Balancing Diagram

Question 24

How can you see the Bottleneck of a process?
a)​The step with the most inventory
b)The earliest step where WIP inventory gathers
c)The step with a steady amount of inventory
d)The step with no inventory

Answer 24

b) The earliest step where WIP inventory gathers