SCM 4367 Midterm 1 material

In the Toyota/Ace Metal Crafts Video that you just watched, the company utilized Lean principles to achieve amazing productivity gains such as producing an entire product that used to take 6 days in only 6 minutes. In order to achieve these results, the video suggests that the company used:

-Small improvements developed by everyone

-"Simple stuff", like tape and signs

[Value-Driven Process Management Article] To alter the level of value offered by a firm, we must:

identify the critical processes and rethink these processes or revise them.

[Week 1 PPT & Video] In the Hurricane Sandy Food Distribution video within the lecture, the Toyota consultants reviewed the amazing results (such as reducing the time to pack a box from 3 minutes to 11 seconds and being able to feed 400 more families in less than half the time) and exclaimed:

"Although the list is shorter than when we started, we still have plenty of homework."

[LS Memory Jogger] Lean Six Sigma is a management system that focuses on:

providing value to our customers by removing all waste, overburden, and variation from our processes.

[LS Memory Jogger] To achieve its objectives, Lean Six Sigma focuses on:

applying principles instead of just pursuing results

[LS Memory Jogger] A deployment strategy used to enable rapid development and replication of Lean Six Sigma countermeasures is referred to as

Model or Learning Line

[LS Memory Jogger] PDCA and DMAIC are both methodologies based upon the principle:

Embrace scientific problem solving

[LS Memory Jogger] The following deployment methodology brings together a small group of people to improve current processes and fix problems very quickly; typically over a period of 2-5 days:

Kaizen Event

[LS Memory Jogger] The goal of any Lean Six Sigma deployment is:

that everyone becomes a capable agent who contributes to improve cost, quality, and delivery every day.

[LS Memory Jogger] The (abbreviated) "five steps" of the Lean Six Sigma Improvement is

Define Value, Observe, Make Flow, Enable Pull, Seek Ideal State (DOMES)

[LS Memory Jogger] When implementing lean, managers should focus their time and efforts on influencing:

the 60% of employees who are undecided about whether they should participate in lean.

[Value Driven Process Management Article] A process transforms

inputs into outputs

[Value Driven Process Management Article] The vehicle by which value is put into operation and delivered to the customers is:

the process.

[Week 1 PPT and Video] It is especially important that value be defined:

in the eyes of the customer, in terms that are meaningful to the customer.

[Week 1 PPT and Video] The "ideal" from a lean perspective is:

perfect quality, zero waste and perfect customer satisfaction

[Week 1 PPT and Video] The traits that the customer expects: the minimum traits needed for a customer to consider your product or service are called:

Order Qualifiers

In the Toyota/Ace Metal Craft Video you just watched, this company utilized Lean principles to greatly improve the company's performance and profits. As a result of these improvements, Ace Metal Craft was able to

Keep the original workers and hire 20 more.

[Value-Driven Process Management Article] The value-driven process is:

never-ending. After an improvement is made, it is time to repeat the improvement process.

[Value-Driven Process Management Article] The process of value-driven process management begins with:

identifying the customer and their order winners, order qualifiers, and order losers.

[Week 1 PPT & Video] In the Starbucks video, "it all comes down to the last 10 feet" is an acknowledgment of

the journey the coffee bean has been on within the Supply Chain

[Week 1 PPT & Video] In the Starbucks video, the barista mentions that making coffee is not like manufacturing. However, the professor mentions that making coffee does have some similarities to manufacturing. All of the following were mentioned as demonstrating coffee making similar to manufacturing EXCEPT:

Coffee making involves personal contact with the customer

[Week 1 PPT and Video] Eli Whitney's contribution to Ford's Mass Production System is:

the interchangeable part

[Week 1 PPT and Video] The five steps of the Six Sigma standardized improvement process in order are:

Define, Measure, Analyze, Improve, Control

[LS Memory Jogger] According to the Lean Six Sigma memory jogger, the best approach for developing capable people is to blend lean monitoring (teaching) with:

learning by doing

[Value Driven Process Management Article] Value can be defined as the:

subjective evaluation of performance of a product, good, or service adjusted by cost.

[LS Memory Jogger] The following are all key points for overcoming resistance to change EXCEPT:

Use a variety of charismatic leaders to help implement the change process.

[LS Memory Jogger] A major failure of most Lean Six Sigma deployment efforts is

That gains achieved are not sustained

[Value Driven Process Management Article] Order Winners are any traits that:

if provided by the product and its processes, will win orders

[Week 1 PPT and Video] TPS: Toyota Production System is sometimes referred to as the:

Thinking People System

[Week 1 PPT and Video] In a lean organization, mistakes are seen as:

opportunities to improve

[Week 1 PPT and Video] Lean improves an organization at a macro-level by

establishing a foundational culture of continuous improvement

[Week 1 PPT and Video] Typical Lean and Six Sigma organizational results, such as 95% lead time reduction, 80% increases in quality, and 60% reduction in costs can be achieved by using:

Existing employees and existing technology

[Week 1 PPT and Video] Processes contain all of the following characteristics EXCEPT:

the very best processes are always automated with robotics and technology

[Week 1 PPT and Video] Most companies know that Lean and Six Sigma are associated with world class performance. Some experts estimate that what percentage of companies have fully utilized Lean and Six Sigma tools, techniques, and and concepts in a meaningful and effective way?

4%-6%

[Week 1 PPT and Video] In order to alter the value delivered to a customer, you must:

alter the process(es) used to create the value

[LS Memory Jogger] The role of people (line workers) in pursuit of lean improvement is to:

be responsible to transform their own processes using the 5 improvement steps.

The following is the best statement describing how Paul Akers explains why people at FastCap are willing to improve their processes

Because improving your processes makes your life better and improves the lives of the people around you

Within the video that you just watched, Paul Akers uses a process where you must complete the following task prior to becoming an employee:

Actually work at FastCap (paid) for one week, interacting with the other FastCap employees

Within the video you just watched, when Paul Akers talks about "leveling the organization", he mentions that the most important people in the organization are the

The people on the shop floor that are actually creating value

Within the video you just watched, Paul Akers explains how he manages the FastCap workers who are working from home during the COVID pandemic. He:

trusts them because he trained them

Within the video you just watched, Paul Akers mentions that the byproduct (NOT the target or goal) of lean is

Economic (profit and revenue) success

[Week 2 PPT and Video] PDCA is an improvement cycle that is the same (or similar to) (Planning, Doing, Checking, Acting)

the Scientific Method

[Week 2 PPT and Video] Craft Production is most often associated with:

Quality and production improvements initiated and developed by the worker

[Week 2 PPT and Video] Craft Production is most often associated with:

Process speed determined by the worker

[Week 2 PPT and Video] Craft Production is most often associated with:

Low Labor Specialization and High Labor Knowledge

[Week 2 PPT and Video] Craft Production is most often associated with:

Small space requirements using inexpensive, general purpose tools

[Week 2 PPT and Video] Mass Production is most often associated with:

High Labor Specialization and Low Labor Knowledge

[Week 2 PPT and Video] Mass Production is most often associated with:

Process speed determined by the manager

[Week 2 PPT and Video] Mass Production is most often associated with:

Large space requirements using expensive, specialized tools

[Week 2 PPT and Video] Mass Production is most often associated with:

Quality and production improvements initiated and developed by management

[Week 2 PPT and Video] One of the characteristics of a Lean Production System is that workers typically:

Perform a variety of tasks and have and have an understanding of the variety of processes that occur around them.

[Week 2 PPT and Video] In the ideal Lean System, process speed is determined by:

the customer

[Week 2 PPT and Video] In the "morning meeting" video at the end of the lecture, Paul Akers describes the title he gives to every employee:

Process Engineer

In the "morning meeting" video shown at the end of the lecture, Paul Akers declares that the purpose of the morning meeting is to

Grow people

[Week 2 PPT and Video] The following best represents a lean "organism perspective" on process optimization:

Lean organizations realize that optimization results are limited because market conditions are constantly changing

[Week 2 PPT and Video] One major difference between Toyota's Prod. System and Ford's Prod. System described in the introductory video, "How Toyota changed the Way we Make Things" enables Toyota to dramatically reduce errors and quality problems on the assembly line. While Ford's system addressed any quality problems or errors at the end of the production process, Toyota's system

encouraged workers to stop the assembly line to identify and solve problems during production

[Week 2 PPT and Video] The introductory "How Toyota Changed the way we make things" video, descrived how Eiji Toyoda and Taiichi Ohno traveledto the US and visited Ford's large River Rouge Factory complex. While on their visit, they were especially impressed but the stocking system used within:

a Piggly Wiggly Grocery store

[Week 2 PPT and Video] Six Sigma concepts were originally developed and adopted in the 1980s and 1990s at two organizations:

Motorola and General Electric

[Week 2 PPT and Video] In a lean organization, the following individuals are encouraged and trained to discover and solve problems and make production improvements:

All employees, regardless of job role are encouraged and trained to discover and solve problems and make production improvements.

[Week 2 PPT and Video] The following were all challenges for Toyota as they started planning their production of automobiles EXCEPT:

Japanese workers were not willing to work in manufacturing plants.

[Week 2 PPT and Video] From an organism viewpoint, the following is more important that optimization:

Flexibility

[Week 2 PPT and Video] From the lean "organism perspective", the best time to take care of a problem is as soon as it occurs. One reason for that is that:

Problems are easier to solve as soon as they occur.

[Week 2 PPT and Video] An "organism viewpoint" refers to each of the following assumptions about organizations EXCEPT:

Organizations must increasingly consume more resources in order to grow and change

[Week 2 PPT and Video] The following is a typical (and prevalent) behavior of employees within a "Mass Production" organization:

Blame and hiding problems

[Week 2 PPT and Video] A change in organizational culture typically originates with:

A change in management beliefs

[Week 2 PPT and Video] In Henry Ford's Mass Production System, workers were treated like:

an interchangeable part that could be discarded and replaced

[Week 2 PPT and Video] The Toyoda family business was not initially making cars, they made:

Looms for weaving cloth

[Week 2 PPT and Video] When a company utilizes lean tools and production techniques WITHOUT the managers and employees adopting a lean MINDSET

The organization will still exhibit the production problems seen in the Charlie Chaplin video

[Week 2 PPT and Video] The most important advantage of a "Lean Organization" over a "Mass Production Organization" is

The culture, where every employee has a lean mindset

[Week 2 PPT and Video] Craft production is most often associated with:

Quality and production improvements initiated and developed by the worker

[Week 2 PPT and Video] Mass production is most often associated with:

Quality and production improvements initiated and developed by management

[Week 2 PPT and Video] The "no layoff" policy often (although not always) adopted by lean organizations is used:

to encourage line employees to participate in creating organizational improvements

Henry Ford's River Rouge plant was so large, it had all of the following characteristics EXCEPT:

The tallest building in the world (at the time)

The Mass Production (Ford) method of production:

Represented World Class production methods in the early 1900s

[Week 2 PPT and Video] The "Mass Production System" is typically seen as being initially implemented within

Henry Ford's automobile production

Within the video you just watched, Paul Akers mentions that the byproduct (NOT the target or goal) of lean is:

Economic (profit and revenue) success

To improve the process in the video you just watched from 46 seconds to 12 seconds:

Several people experimented and tried many very small changes. Several of the small improvements only saved one or two seconds.

Within the video you just watched, every time the group tried a change in the process with a goal of improving:

The group learned, even though sometimes the experiment resulted in a process time that was longer

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul explained that the moment he knew that he did not know anything about effective production processes was when the Japanese consultants were able to transform a 45 minute process to only take:

5 minutes

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul clearly addresses the common misconception that Lean is the same as

OCD: Obsessive Compulsive Disorder

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, there was a moment that Paul paused to discuss why he was so intentional about the way he put a piece of paper back into a slot on a shelf. He stated that when he carefully made sure that the paper was in the right place and in the right orientation, he was practicing the Lean principle of:

Respect for people

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul described how the most basic principle to learn about Lean is to be able to

see waste and eliminate it

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul described how when top managers have the following attitude, they will kill a lean effort (the lean effort will fail). [NOTE: The correct answer to this question is the attitude that PAUL describes as killing lean efforts.]

Doing Lean with the goal of making a profit

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul mentioned that the most important tool his people use (which they do at the very beginning of every day) is

3S (the first three steps of 5S)

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul states that the best lean leaders get ___________ to do lean

everyone in the organization

[Waste Definitions Handout] According to the definitions of waste, the following statement about waste is FALSE:

Waste reduction is the same as cost reduction

[Week 3 PPT and Video] Within the manufacturing demonstration during class, Dr. Miller described how the "tool crib manager" is working in:

A cage

[Waste Definitions Handout] In a manufacturing operation, the following is an indication of waste:

a part or material that is not being transformed (having value added)

[Week 3 PPT and Video] In practicing "Gemba", if an organization has a problem or a decision to make, the first thing to do is:

the manager should go spend time in the actual workplace

[Waste Definitions Handout] The number of transport and material handling operations is:

directly proportional to the likelihood of damage and deterioration

[Waste Definitions Handout] The following resource has the potential benefits of avoiding bottlenecks, improving flow, improving simplicity, increasing the flexibility of maintenance, improving cash flow, and enhancing technology adoption:

Smaller machines

[Week 3 PPT and Video] Within the video lecture, Dr. Miller mentioned that Toyota claims that if every worker at one of their car plants were to figure out a way of saving just one seconds, the plant would be able to produce:

eight more cars per shift

[Week 3 PPT and Video] When improving a process using Lean principles, we would prefer that, in the improved process, a worker does the Value Added tasks in the process:

Slower

[Week 3 PPT and Video] The purpose of lowering the level of "water" in the river and rocks metaphor is to

make problems happen so that we can see where to improve

[LS Memory Jogger] Value from a customer perspective may be defined as:

A change in form, fit or function of the product or service

[Week 3 PPT and Video] The process of going to the actual workplace, looking at the actual process, observing what is actually happening, and collecting the actual data is referred to as:

Gemba

[Week 3 PPT and Video] Producing or buying more than the customer needs before the customer needs it is called:

Overproduction

[Week 3 PPT and Video] Moving materials without transforming them is called:

Transportation

Within Paul Akers' "Path to Success" video where he was explaining his production system in the UpFlip interview, Paul explained how his company is missing a lot of features of a typical company. The only item in this list below that Paul DOES have in his company is:

Clearly Defined Process

[Week 3 PPT and Video] Brushing your teeth is an example of a transformation process (transforming dirty teeth into clean teeth). In the process for brushing teeth that is described below, which of these steps is considered Value Added (VA):

-Scrub your teeth with the toothbrush