Chapter 24: Lean

1. Womack and Jones (1996) summarized their approach to lean in five principles. Which of the following is the first?

Identify value streams for each product to expose waste Precisely specify value for each product or product family Make value flow without interruption Pursue perfection by searching out and eliminating further waste

2. Some practitioners view lean as a set of tools and techniques, whereas others view it as:

a set of tactics a philosophy a hypothesis an assumption

3. Although originally developed in the context of manufacturing, lean thinking has spread beyond the shop floor and is now widely applied in sectors such as:

finance health education all of the above

4. What important limitations did Henry Ford’s assembly line have?

The production system could not respond to customers’ demands for more variety Product development was a slow process Almost all machines involved in fabricating components only produced a single part All of the above

5. Sakichi Toyoda, the founder of the Toyota Group, invented a loom that automatically stopped if a thread snapped. This led to the development of other:

machines for clothes production automated looms self-monitoring machines types of production lines

6. Taiichi Ohno, an engineer at Toyota, developed JIT scheduling systems driven by _____________ rather than ____________.

customer demand/sales or production targets sales/customer demand quality/quantity All of the above

7. Specifying value is the essential first step in lean thinking and needs to be done from the perspective of ________________.

resources shareholders the end customer cost-cutting

8. According to Womack and Jones (1996), target cost is the amount of resource and effort required to produce the product or service to the required specification:

once all currently visible waste is removed from the process after all waste is identified including any waste None of the above

9. Type one waste includes:

all activities that fail to add value but are immediately avoidable some of the activities that add value but are still deemed wasteful activities that create no value but are unavoidable activities that have been classed as wasteful in the past but may now add value

10. The pull principle involves no one producing anything until:

someone downstream requests it all resources needed to produce it are available all waste has been removed it is cost effective to do so

11. The ongoing search for continuous improvement is known as:

the push principle Kaizen Mottainai total productive maintenance

12. Jidoka involves:

relying on machines to fix problems as part of the production processes fixing problems at the end of the production line workers stopping production and immediately fixing problems as they occur making fundamental and radical changes to a production system

13. Which of the following is NOT one of Taiichi Ohno’s seven wastes?

Overproduction Waiting Inventory Illness

14. Which of the following is NOT one of the 5Ss?

Separate Sweep Standardize Segregate

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