102 Questions
What is Lean focused on identifying and eliminating?
Waste
Why do over half of Lean initiatives fail?
Inadequate management support
How should Lean be thought of, according to the text?
As a long-term health program
What is a common reason that management fails to support Lean initiatives?
Lack of dedicated resources
What is the viewpoint used to identify waste in Lean?
Customer's perspective
How can Lean be described in terms of improvement approach?
"Bottom-up" approach
What is the purpose of 'Plan' in Supply Chain and Logistics Management?
Balancing supply and demand
Which stage involves the procurement of goods to meet demand?
Source
What does the 'Make' stage involve in Supply Chain and Logistics Management?
Transforming raw materials into finished products
Which activity is included in the 'Deliver' stage of Supply Chain and Logistics Management?
Order management
What is one reason for the interest in Lean Supply Chain Management mentioned in the text?
To reduce costs in the supply chain
What percentage of the cost of sales does the text mention the supply chain accounts for?
50% to 80%
What is a key requirement for implementing Lean?
Both top-down management commitment and bottom-up participation and ideas
How is Lean typically implemented?
Through a train-do method
What was Lean originally applied to?
Manufacturing industry only
According to the CSCMP, what does supply chain management encompass?
Planning, management of all activities, sourcing, procurement, conversion, and logistics management
How does the SCOR Model divide the supply chain?
Into five management processes
What term is commonly used today to refer to Lean applied across an entire organization?
Lean Enterprise
What is the Bullwhip effect in supply chain management?
A magnified effect when orders move up the supply chain
Why do companies need to reduce costs and make their supply chain operations more efficient?
To meet customer demands for shorter lead times and lower prices
What effect does a 1-dollar supply chain cost reduction have on profit margin compared to a sales increase of 4 dollars?
Same impact on profit margin
How has the increased use of outsourcing and global supply chains impacted supply chain professionals?
Added exposure and importance to the function
What can cause the Bullwhip effect in supply chains?
Variance in lead times
In lean supply chain management, what do customers typically demand from companies?
Shorter lead times, smaller order quantities, and lower prices
What is the main reason for the interest in Lean Supply Chain Management mentioned in the text?
Financial reasons
What percentage of the cost of sales does the supply chain typically account for, according to the text?
50 to 80 percent
What is the primary reason for the failure of over half of Lean initiatives?
Lack of the proper culture to support major changes
What stage involves the transformation process of taking raw materials and converting them into finished products?
Make
How is Lean different from a crash diet, according to the text?
Lean should be thought of as a long-term health program for business.
What is included in the 'Deliver' stage of Supply Chain and Logistics Management?
Order management, warehousing, and shipping
What is the main focus of Lean continuous improvement?
Identifying and eliminating waste.
What is the purpose of the 'Return' stage in Supply Chain and Logistics Management?
Reverse logistics process for returned products/materials
Why do some organizations view Lean as a 'fad' or a short-term program?
Management may not be willing to give up control to workers or dedicate resources for training and improvements.
What is one key requirement for implementing Lean, as mentioned in the text?
Management support
In Lean Supply Chain Management, what does 'Lean' emphasize in terms of improvement?
Continuous improvement through waste elimination.
What are some of the challenges organizations face when managing the supply chain amidst disruption?
Political, financial, environmental, and other unplanned events.
Why is it mentioned that a company would need to increase sales by 4 dollars to have the same impact on the profit margin as a 1-dollar supply chain cost reduction?
Due to the 10 percent profit margin and the supply chain cost being 60 percent of sales.
What is the Bullwhip effect in supply chain management?
The magnified effect that occurs when orders move up the supply chain.
What are some factors that can cause the Bullwhip effect in supply chains?
Forecast errors, large lot sizes, panic ordering, variance in lead times, etc.
What are some demands that customers typically have in lean supply chain management?
Shorter lead times, smaller order quantities, and lower prices.
Why has the increased use of outsourcing, global supply chains, e-commerce, and shorter product life cycles been a double-edged sword for supply chain professionals according to the text?
It has given added exposure and importance to the function but also put pressure on the supply chain to be efficient amidst complexity.
What is one reason mentioned in the text for the interest in Lean Supply Chain Management?
Customers wanting shorter lead times, smaller order quantities, and lower prices.
What is the importance of having both top-down and bottom-up commitment in implementing Lean?
Encourages change and participation, fosters continuous improvement mentality
How is Lean typically implemented using a train-do method?
Through a trainer or consultant acting as a facilitator to teach basic concepts and tools
What is the historical background of Lean application in industries?
Lean was first applied to manufacturing, then to office processes and supply chain
How does the Council of Supply Chain Management Professionals define supply chain management?
Encompasses planning, sourcing, procurement, conversion, and logistics management
What are the five management processes that the SCOR Model divides the supply chain into?
Plan, Source, Make, Deliver, Return
Why is Lean often referred to as Lean Enterprise today?
Due to its application across the entire organization
What is the primary reason for the failure of over half of Lean initiatives?
Lack of proper culture to support major changes required
Why do some organizations view Lean as a 'fad' or a short-term program?
Believing it will go away or considering it a temporary trend
What does 'Lean' emphasize in terms of improvement in Lean Supply Chain Management?
Identifying and eliminating waste
How is Lean different from a crash diet, according to the text?
Lean is a long-term health program for business, not a short-term solution like a crash diet
What is one reason mentioned in the text for the interest in Lean Supply Chain Management?
Tremendous opportunities in managing supply chain amidst disruptions
How is Lean typically implemented?
As a team-based form of continuous improvement
Why is it important for Lean implementation to have both top-down management commitment and bottom-up participation?
Encourages a team-based continuous improvement mentality
What is the historical background of Lean application in industries?
Initially applied to the manufacturing industry
How is Lean typically implemented using a train-do method?
Trainer teaches basic concepts and tools, employees continue the journey
What term is used today to refer to Lean applied across an entire organization?
Lean Enterprise
What does the Council of Supply Chain Management Professionals define as supply chain management?
Planning and management of all sourcing, procurement, conversion, and logistics activities
How does the SCOR Model divide the supply chain?
Into five management processes
What is the purpose of the 'Return' stage in Supply Chain and Logistics Management?
The purpose is to manage the reverse logistics process for returned products or materials, including repair, maintenance, and overhaul.
How is Lean different from a crash diet, according to the text?
Lean is a continuous improvement approach focused on identifying and eliminating waste, while a crash diet is a short-term program or 'fad'.
What is the significance of top-down and bottom-up commitment in implementing Lean?
Both top-down and bottom-up commitment are crucial for successful Lean implementation as they ensure support and involvement at all levels of the organization.
What are some challenges organizations face when managing the supply chain amidst disruption?
Organizations may face challenges such as supply chain disruptions, demand fluctuations, inventory management issues, and maintaining operational efficiency.
How should Lean be thought of, according to the text?
Lean should be viewed as a continuous improvement philosophy rather than just a set of tools or techniques.
What is the primary reason for the interest in Lean Supply Chain Management, as mentioned in the text?
The primary reason is financial, as reducing supply chain costs can have a significant impact on profitability.
What is the impact of a 1-dollar supply chain cost reduction compared to a sales increase of 4 dollars on a company's profit margin?
They have the same impact on the profit margin.
What factors can cause the Bullwhip effect in supply chains?
Forecast errors, large lot sizes, panic ordering, variance in lead times, etc.
Why do customers demand shorter lead times, smaller order quantities, and lower prices in lean supply chain management?
To meet their needs and preferences.
What are some challenges faced by organizations when managing the supply chain amidst disruption?
Maintaining efficiency while dealing with increased complexity.
What is the impact of the increased use of outsourcing, global supply chains, e-commerce, and shorter product life cycles on supply chain professionals?
It has given added exposure and importance to the function while putting pressure on efficiency.
What is a key requirement for implementing Lean Supply Chain Management?
Reducing costs and making supply chain operations more efficient.
What is considered waste in a process according to the text?
Activities that do not add value like waiting in line
Which waste is needed to compensate for lead times and variability in the system?
Inventory Waste
What is the purpose of Inventory Waste in a supply chain system?
To buffer between suppliers, manufacturers, and customers
Which of the following is NOT considered one of the Eight Wastes mentioned in the text?
Efficiency Waste
What type of activities are typically classified as waste according to the text?
Activities that do not add value like overprocessing
Which of the following is a common reason for waste in a process based on the text?
Waiting for materials to arrive from suppliers
What is the main cost associated with maintaining inventory?
Insurance and storage costs
Which of the following is considered a type of inventory?
Machinery spare parts
What are the four types of inventory mentioned in the text?
Raw materials, Work-in-process, Finished goods, Materials, Repairs, Operations
Which waste is associated with transporting materials multiple times before consumption?
Motion Waste
What are the costs that make up holding or carrying costs of inventory?
15% to 30% of product value
Which type of inventory includes purchased materials and components?
Raw materials
What does the concept of motion waste emphasize?
Having just enough material or information nearby and replenishing when needed from afar
How does the text describe the concept of 'Point-of-use storage'?
Having just enough material or information nearby for immediate use
Why is ergonomics important in reducing motion waste?
To optimize how humans interact with equipment and the workplace
How does the text define the foundation concepts of layout and visual workplace?
Stressing the significance of proper flow and organization in different environments
What risk is associated with returning material to a different spot?
Risk of losing material and accidentally ordering more
How is waste defined in relation to motion in the text?
Minimizing unnecessary movements that do not contribute to value creation
What is Waiting Waste in Lean Supply Chain Management?
Time spent waiting on materials, supplies, information, and people needed to finish a task
Where can Waiting Waste be found?
On the shop floor, in a warehouse, or in an office
What is Overproduction Waste in Lean Supply Chain Management?
Manufacturing something before it is actually needed
What can cause Overproduction Waste?
Long setup times
In which stage of the process can products sit 'waiting' according to the text?
All of the above
What is the primary difference between Waiting Waste and Overproduction Waste in Lean Supply Chain Management?
Waiting Waste relates to time delays, while Overproduction Waste pertains to early production.
What does the waste of defects in manufacturing primarily refer to?
Repairing, reworking, or scrapping materials
In the office and warehouse, what can be considered defects or errors?
Errors in data entry and standardized work
What is one of the causes of defects or errors according to the text?
Too much variations
What is the significance of employee creativity in eliminating the other seven wastes?
It helps eliminate the other seven wastes
What is the purpose of emphasizing employee creativity and participation in a company?
To reduce various types of wastes
Why are defects further along in the process considered more costly to companies?
Because they require reworking or scrapping materials
Study Notes
What is Lean?
- Lean is a team-based form of continuous improvement that focuses on identifying and eliminating waste.
- Waste is non-value-added activity from the customer's viewpoint.
- Lean should be thought of as a long-term health program for business, not a crash diet.
Lean Failure
- Over half of Lean initiatives have failed.
- The primary reason for this is the lack of the proper culture to support the major changes required.
- Management may not be willing to give up some control to workers, dedicate resource time, or spend money for training and improvements.
- Lean is sometimes viewed as a “fad” that will go away or a short-term program.
Implementing Lean
- Lean requires both a top-down management commitment to change and a bottom-up participation and ideas.
- The culture has to encourage and create a team-based continuous improvement mentality.
- An effective way to implement Lean is through a train-do method, where the trainer or consultant teaches employees the basic concepts and tools.
- Lean began to be applied to the manufacturing industry (Lean Manufacturing), the office for administrative processes (Lean Office), and recently to the supply chain and logistics function (Lean Enterprise).
Supply Chain and Logistics Management
- Supply chain management encompasses the planning and management of all activities involved in sourcing, procurement, conversion, and logistics management.
- The Supply Chain Operations Reference (SCOR) Model divides the supply chain into five management processes:
- Plan: Balancing supply and demand.
- Source: Procurement of goods to meet demand.
- Make: Transformation process, taking raw materials and converting them into finished products.
- Deliver: Resources to move materials along the supply chain.
- Return: Reverse logistics process for product or material that is returned.
Why All the Interest in Lean Supply Chain Management?
- The first reason is financial: the supply chain is a major cost center, ranging from 50 to 80 percent of the cost of sales.
- Reducing costs by a relatively small percentage can have the equivalent contribution to profit of increasing sales by a much larger percentage.
- The second reason is operational: the bullwhip effect describes the magnified effect that occurs when orders move up the supply chain.
- Increased use of outsourcing, global supply chains, e-commerce, and shorter product life cycles has added pressure on the supply chain to be efficient while it has become stretched and more complex at the same time.
The Eight Wastes
- Waste: anything that does not add value to a process.
- The eight wastes are applicable to any process, whether it is manufacturing, administration, or transportation.
- The eight wastes are:
- Inventory Waste
- Transportation or Movement Waste
- Motion Waste
- Waiting Waste
- Overproduction Waste
- Overprocessing Waste
- Defect or Error Waste
- Behavioral Waste (Underutilized Employees)### The Eight Wastes
- The Eight Wastes are categorizations of excess movement or actions in a process that do not add value to the product or service.
Transportation Waste
- Transportation Waste occurs when materials are moved unnecessarily, affecting inventory accuracy and increasing the risk of damage or loss.
- Companies pay for each move, and the material may be moved to a different location, increasing the risk of losing it and accidentally ordering more.
Motion Waste
- Motion Waste refers to any motion that does not add value to the product or service.
- The concept of motion waste is about having frequently used items closer and less frequently used items further away and higher up.
- Point-of-use storage means having just enough material or information nearby, which can be replenished when needed from further away.
- Ergonomics is important in motion waste, considering not only efficiency but also safety.
Waiting Waste
- Waiting Waste is time spent waiting on materials, supplies, information, or people needed to finish a task.
- This waste can occur in various environments, including the shop floor, warehouse, or office.
- A significant part of a product's or service's lead time is spent waiting, often due to long setup times, large batch sizes, and downtime.
- Examples of waiting waste include waiting for equipment to start up, computer breakdown, signatures, or employees on different work schedules.
Overproduction Waste
- Overproduction Waste occurs when manufacturing, ordering, or processing something before it is actually needed.
- This typically results in an excess of major waste.
Defect or Error Waste
- In manufacturing, defect waste refers to repairing, reworking, or scrapping materials due to errors.
- The further along a defect gets, the more costly it is to the company.
- In the office and warehouse, defect waste can include errors made during data entry, receiving, and picking and shipping the wrong product.
- Causes of defect waste include poor processes, too much variation, supply issues, insufficient or improper training, and tools and equipment not properly calibrated or precise.
Behavioral Waste
- Companies need employee creativity and participation to eliminate the other seven wastes.
- Behavioral waste is closely related to the elimination of the other seven wastes.
Test your knowledge on key concepts in supply chain and logistics management including planning, sourcing, making, and delivering materials throughout the supply chain.
Make Your Own Quizzes and Flashcards
Convert your notes into interactive study material.
Get started for free
