1. Does lean operation rely on implicit or explicit production planning? 2. Is a lean operation considered a push or a pull system?

Transcription

1 1. Does lean operation rely on implicit or explicit production planning? 2. Is a lean operation considered a push or a pull system? 3. Does lean operation rely more on precise calculations or reaction to signals? 4. Push versus pull refers to pushing or pulling what? 5. Muda is another term for what? 6. In a dual card kanban system, one kind of card represents permission to produce. What does the second type of card represent permission to do? 7. What does reducing the number of kanban cards circulating in a single card kanban loop reduce? Chapter Twelve, Lean Operations, Minute Answer Questions #1 to 12 PDF A1M120-01

2 8. Lean refers to less what? 9. An employee says, I ve got to get back to work now. I ve got to calculate how many of each kind of part the factory needs to make next week. Then I ve got to fill out all those work orders and make sure everybody out in the factory gets one. What word or words best describe the type of inventory control system this employee supervises? 10. What is the ideal order size in a lean/jit environment? 11. Revising a process such that its desired outcome is the only outcome possible, also known casually (and rather inaccurately) as dummy proofing or mistake proofing, is a principle known formally as what? 12. Will implementing leaner practices likely increase or reduce the frequency of ordering materials? Chapter Twelve, Lean Operations, Minute Answer Questions #1 to 12 PDF A1M120-01

3 The usage rate D of a component is 200 an hour, the lead time L on a container of the component is 1 hour, and each container holds 110 components. Assuming a policy variable X of 0.10, how many kanban cards should be used to control production? The usage rate D of a component is 200 an hour, the lead time L on a container of the component is 1 hour, and each container holds 22 components. Assuming a policy variable X of 0.10, how many kanban cards should be used to control production? Chapter Twelve, Lean Operations, Quick Start Questions #13 to 15 PDF A1Q121-01

4 The usage rate D of a component is 200 an hour, the lead time L on a container of the component is 1 hour, and each container holds 22 components. Assuming a policy variable X of 0.21, how many kanban cards should be used to control production? Chapter Twelve, Lean Operations, Quick Start Questions #13 to 15 PDF A1Q121-01

5 Five hundred of part A and 2,000 of part B are used annually. If the job shop that creates and uses these parts operates 250 working days a year, level scheduling requires the shop to create how many of each part each day? Chapter Twelve, Lean Operations, Quick Start Question #16 PDF A1Q122-01

6 2 nd Edition An item arrives for processing at an average rate of 200 items an hour (λ), where each item spends an average of 30 hours (W) being processed. On average, how many items are in the processing system? An item arrives for processing at an average rate of 200 items an hour (λ), where each item spends an average of 30 minutes (W) being processed. On average, how many items are in the processing system? An item arrives for processing at an average rate of 100 items an hour (λ), where each item spends an average of 30 minutes (W) being processed. On average, how many items are in the processing system? Chapter Twelve, Lean Operations, Quick Start Question #17-#19 PDF A2Q123-01

7 One common illustration used to demonstrate the philosophy of just-in-time inventory management shows a lake in which sharp rocks are hiding beneath the water s surface. What do the rocks represent? One common illustration used to demonstrate the philosophy of just-in-time inventory management shows a lake in which sharp rocks are hiding beneath the water s surface. What does the water represent? Why should the lake be drained? Chapter Twelve, Lean Operations, Ramp-up Questions #20 to 21 PDF A1R121-01

8 The usage rate of a component is 600 an hour, the lead time on a container of the component is 30 minutes, and each container holds 110 components. Assuming a policy variable of 10%, how many kanban cards should be used to control production? Chapter Twelve, Lean Operations, Ramp-up Question #22 PDF A1R121-02

9 A kanban system has just been introduced into a machine shop to control the production of a common part used by many different subassemblies at many different workstations. The kanban system has been operating for 2 weeks, but workers have made many complaints about it. Apparently workers who build the subassemblies cannot always find that part in stock exactly when they need it. How can the kanban system be adjusted to address these complaints? Three kanban cards are hanging on a board next to a work area, while another identical kanban card is attached to the container that an employee is busy filling with parts created in that work area. Five more matching kanban cards are already attached to full containers placed in a convenient waiting area near this work area. A supervisor walks over, removes two of the kanban cards from the board, and puts them in her pocket. The supervisor then walks away. Which is the best explanation for why the supervisor did that? Chapter Twelve, Lean Operations, Ramp-up Questions #23 to 24 PDF A1R121-03

10 The Belmont Company must produce 1,500 boxes of product A each year, 2,000 boxes of product B each year, and 500 boxes of product C each year. The Belmont Company works 250 days a year, and it can make a total of 16 boxes of product a day (any mix of the products A, B, and C). In the past, Belmont would spend the first of the year producing just product A, then producing just product B when all 1,500 boxes of product A were finished, and then switch over late in the year to produce product C. However, the president of Belmont has decided that the company should follow the principles of lean operations, including smoothing production of the demand requirements of these three products into mixed-model scheduling. a. When Belmont uses its traditional schedule, how many days does it spend making product A at the beginning of the year? When it switches then to product B, how many days does it spend producing that product? How many days are then required to finish the batch of product C? Chapter Twelve, Lean Operations, Scenario Question #25 PDF A1F122-01

11 b. If Belmont implements a perfectly smooth, mixed-model schedule, it will produce the same mix of three products every day. How many of each product should be in this daily mix? c. Ideally, in what order should this new daily mix be completed during the day? Chapter Twelve, Lean Operations, Scenario Question #25 PDF A1F122-01

12 The fabrication department provides a component for the assembly department. The assembly department s usage of the component is 4,800 units per 8-hour day. The fabrication department fills each container with 60 units in 40 minutes. Management has built a 20% cushion into the system. a. How many containers (or kanban cards) should be used for this component? b. Next month, the fabrication department expects its own usage of the component to fall by half, due to an expected decrease in sales of the finished goods requiring that component. Assuming that this change is permanent, how should the number of containers (or kanban cards) used to control this component be adjusted? Chapter Twelve, Lean Operations, Scenario Question #26 PDF A1F121-01

13 2 nd Edition Darden Company uses a Kanban loop to control SKU #303, which is produced on stamping machines. They have six kanban cards circulating in the loop, and are happy with the performance of the system so far. However, the production floor manager has just approached you to express her concern over a change that will take place next month: Darden will replace these stamping machines with a newer technology that can produce SKU #303 at twice the speed as the current machines. Darden uses a policy variable of 10% when determining the number of cards in a kanban loop, and a container of SKU #303 holds 55 units, while Darden uses an average of 600 units of SKU #303 every hour. a. Assuming that Darden Company is using the optimal number of kanbans for current conditions, how long does it take to fill one container with SKU #303? Chapter Twelve, Lean Operations, Scenario Question #27 PDF A2F122-02

14 2 nd Edition b. How should Darden change the Kanban loop next month, after the installation of the new machinery? Chapter Twelve, Lean Operations, Scenario Question #27 PDF A2F122-02