Meritor is so pleased with the outcome from previous suggestions that the consultants are invited back for more work. The consultants now suggest a more complete robotic automation of the making of muffler assemblies and also a reduction in container size to eight per container. Meritor implements these suggestions and the result is that the muffler assembly fabrication cell now averages approximately 32 assemblies per hour, and the catalytic converter assembly cell can now respond to an order for a batch of catalytic converters in one hour. The safety stock remains at 12.5 percent. How many kanban cards are needed? (Answer in Appendix D)

What are the first two areas that should be identified in value stream mapping?

The lean operations system strategy has been in operation for 3 months at Your Furniture Company. Recently, operations managers have received complaints from the company’s distribution division that customer orders for dining room tables are delayed due to a backup in the production assembly area. The assembly team consists of 30 members, with each member assembling a table from start to finish from the cut pieces provided through upstream production. Using the given Dining Table Assembler (DTA) job design, how does each step in the methods analysis procedure can be used to improve the efficiency of the assembly operation?

How do you Assess 5 lean processes and 5 lean tools for their ability to eliminate waste and lower production costs while maintaining quality using Lean processes, Small lot sizes, Set-up time reduction, Manufacturing cells, Quality improvement, Production flexibility, Balanced system, Little inventory storage, Fail-safe methods?

Briefly explain the process of creating value stream mapping and how it help the organization to improve quality?

The Toyota Production System is founded on these two philosophies. These are ___ a. Internal costs and external cost b. Elimination of waste and respect for people c. Value stream mapping and cost of quality d. Strategic cost and elimination of waste

Provide an example of value stream mapping.

Make a Lean Canvas using a product of Bag made out of recycable material "Recycled Bag" Using this template Problems 1-3 problem of the customer (you can use the 5 why or job to be done technique)   Existing Alternatives How do the early Adopters solve their problem today   Customer Segments Who is your customer (be specific)   Early adopters People that needed your product the most   Solution For each item listed on Problems, provide solution (these solution must be a feature of the product)   Unique Value Proposition What makes your product unique or noticeable You can derive it from your #1 problem Don't focus on feature but rather the finish story benefit (end result of your product)   High-Level concept Memorable tagline   Revenue Stream How will you price your product  Price relative to alternatives Keep it simple   Channels How will you build a path to customer   Key Metrics How to measure the success of your business…

List at least 4 indicators of waste and provide an example of each.   (this question/indication is of lean manufacturing)

What are the quality, inventory, planning and scheduling, lean systems, and sustainability of the Linen Handling Unit?