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An Italian restaurant offers pizza for lunch. The counter holds 10 pizzas made-in-advance for customers to pick up. The restaurant also offers pizzas made-to-order for customers sitting down in the restaurant. What is the most effective configuration for the kitchen?
At a burger restaurant, orders are given to the grill. After the meat is ready, it is moved to the next station to add the bun, salad, tomatoes, and onions. What is the function of the grill?
An engineering company wants to improve inventory management. It standardizes frequently-used office supplies (markers, paper, clips, pens, pencils) for employees to take when needed. Which system is most suitable?
An automotive supplier produces car seats for current BMW models in high volume. The same company also makes seats for legacy cars (1960-1980) to special order. Which system is most suitable?
Apple has many stores where customers can buy customized computers. Orders are sent to the central factory in China to be processed as they were received (first-come, first-serve). The process is highly standardized, lead-times are fixed and reliable. Which system is most suitable?
WatchTec makes watches using three processes: (1) produce case internally, (2) send case to external subcontractor for plating, (3) return plated case for final assembly internally. Which system is most effective for this workflow?
When to use a make-to-order (MTO) or build-to-order (BTO) strategy? Customer tolerance refers to the time the customer is willing to wait.
Which statement is NOT correct about a Sequential Pull system?
Which statement is NOT correct about a Supermarket Pull System?
Which statement is NOT correct about a Mixed Pull System?
FLOWTEC operates 22 days per month, 8 hours per day, blending raw materials into finished goods (see VSM). What is the Takt time? Round-up to full seconds 0-100.
FLOWTEC: How many units are in transit to the customer? Enter full quantity, such as 5000.
FLOWTEC: What is the raw material replenishment lead-time? Consider the process from purchasing/MRP to receiving raw-materials from suppliers. Enter lead-time in days 0-100.
FLOWTEC: Occasionally, a supplier-truck breaks down. How many tons of raw materials should be kept in safety stock in front of Blending to protect the factory from one missing delivery? Assume 3 days replenishment lead-time, order to delivery. Enter full tons 0-100.
FLOWTEC: A customer places an order. Raw materials are available in stock and capacity is available to process the order right away. What is the overall lead-time for one batch of 1000 units? A rough calculation is sufficient, round-up to full days 0-100.
FLOWTEC: How many people are currently working in the company? Consider all processes and disregard the man with the cart as he is already part of the Blending team.
FLOWTEC: A Lean expert eliminates rework and downtime, combines Blending and Packing into one cell, and cross-skills people in manufacturing. How many people are now required in the factory? Consider Blending and Packing.
FLOWTEC: How efficient is the operation overall? Calculate the rolled throughput yield (RTY) or overall efficiency (OEE, OPE) across the value chain. Enter rounded percentage 0-100.
FLOWTEC: What is the non-performance cost (NPC) per day in Planning? Assume $30 labor cost per man-hour and 8 hours per workday.
FLOWTEC: How much labor cost will be saved per day if Blending rework is eliminated? Assume $30 labor cost per man-hour and 8 hours per workday.
During a 10-hour shift, a printer is used for 30 minutes to print 300 pages without any problems. What is the Operational Availability? Enter percentage 0-100.
During a 10-hour shift, a printer is used for 30 minutes to print 300 pages without any problems. What is the Operating Rate? Enter percentage 0-100.
The same printer has a 6-minute paper-jam, during the 30-minute use-time, over the 10-hour day. What is the Operational Availability now? Enter percentage 0-100.
A meeting was scheduled for 1 hour, but took 2 hours. Attendance was 80%. Out of 10 points on the meeting agenda, only 7 were successfully completed. How efficient was the meeting? Use overall efficiency or overall effectiveness formula (OEE, OPE). Enter percentage 0-100.
Starbucks offers a new product, the Latte Special. To make the new drink, the coffee machine runs 40% slower, at 60% of the specified speed. Additionally, the machine must be cleaned for 3 minutes each hour. Out of 100 drinks made, 7 are overfilled. How efficient is the new process? Round OEE in full percentage 0-100.
John received 100 emails: 20 are spam + 30 he was copied without reason + 50 require his response. In average, John needs 0.5 minute to read an email and an additional 3 minutes when he needs to write an answer. What is the average cycle time? Enter minutes 0-100.
A McDonalds kitchen makes hamburgers at a rate of 30 seconds per unit. After producing 300 hamburgers, the kitchen must be cleaned for 30 minutes. What is the effective cycle time in seconds?
After completing a batch of salads, the kitchen is cleaned and prepared for making a batch of desserts. How to define the changeover time?
Every hour, Marks walks through the facility to deliver documents and suppliers, such as printing paper, 100 pages per pack. The central printer consumes one page per minute, in average. At the beginning of the day, the printer was already filled with one complete pack of paper. Determine the optimal Kanban-sequence for an 8-hour day. Ignore breaks. 1 = refill required, 0 = refill not required.
A document-bin is installed between two departments to synchronize one-piece workflow. Which statement is NOT correct?
MagaClean employs 3 cleaners, each at $20 per hour, and 1 manager at $40 per hour. During 8 hours, 100 rooms are being cleaned and inspected, of which 20 rooms require rework, to be cleaned twice within the same workday. How efficient is the cleaning process? Enter percentage 0-100.
MagaClean employs 3 cleaners, each at $20 per hour, and 1 manager at $40 per hour. During 8 hours, 100 rooms are being cleaned and inspected, of which 20 rooms require rework, to be cleaned twice within the same workday. What is the total cost per cleaned room? Enter full dollars 0-100.
MagaClean employs 3 cleaners, each at $20 per hour, and 1 manager at $40 per hour. During 8 hours, 100 rooms are being cleaned and inspected, of which 20 rooms require rework, to be cleaned twice within the same workday. What is the cost of rework? Assume all people contribute equally. Enter rework cost per day in full dollars 0-1000.
MagaClean employs 3 cleaners, each at $20 per hour, and 1 manager at $40 per hour. During 8 hours, 100 rooms are being cleaned and inspected. After a process improvement, 20% rework has been eliminated, so the team cleans additional rooms. By how much does the profit increase per day? Assume customers pay $10 per room cleaned. Enter full dollars 0-1000.
MagaClean employs 3 cleaners, each at $20 per hour, and 1 manager at $40 per hour. During 8 hours, 100 rooms are being cleaned and inspected. After a process improvement, 20% rework has been eliminated, so the team cleans additional rooms. Customers are happy with the new process and reward more business to MagaClean. The manager doubles his cleaning staff, from 3 to 6 people. He can comfortably manage the larger team without overtime. What is MegaClean’s capacity now? Calculate rooms per day 0-1000.
MagaClean’s manager analyzes the cleaning process and finds 20% incidental work (Muda-1) and 30% waste (Muda-2). What is the value-adding percentage? Enter 0-100.
MegaClean’s process consists of 20% incidental work (Muda-1) and 30% waste (Muda-2). What is the cost-savings potential by applying continuous improvement thinking? Enter percentage 0-100.
After landing at the airport, 1000 passengers are waiting for passport control. There are 20 immigration officers on duty. Each officer checks one passenger per minute. How long is the wait time in minutes?
A kiosk opens 24 hours per day. In average, customers buy 30 bottles of Coke per hour. The supplier delivers Coke in pallets of 900 bottles each. What is the replenishment pitch? Assume 1 pallet per delivery. Enter hours 0-100.
A customer orders 100 units. The sales clerk enters 105 units into the system, just in case the customer wants more. The planner sees a demand of 105 units in the system and issues work orders for 110 units. Production makes 115 units to cover potential failures. How is this practice called?
In a production cell, machines eject parts automatically upon completion. An operator takes a completed part from one machine and loads it into the next. How is this practice called?
Employees have clearly defined jobs without overlap. Mary enters orders. After completion, she places them on top of Tom’s inbox, where many documents are already waiting to be processed. How is such system called?
A factory produces 1000 generators per year. Demand is steadily increasing and the sales manager predicts up to 2000 generators will be sold next year, but the forecast is not robust. Which expansion strategy supports Capital Linearity?
Which is NOT a principle of Lean Thinking?
What is NOT correct about Demand Amplification or Bullwhip Effect?
Which is NOT correct about Jidoka?
From a customer perspective, which is NOT an example of incidental work (Muda-1)?
Which is NOT related to Kaikaku?
What is NOT correct about Kanban?
Which is NOT a Kanban rule?