Practice IB Design Technology (DT) Topic 10.2 Lean Production with authentic exam-style questions for both SL and HL students. This question bank focuses on the exact syllabus content for 10.2 Lean Production and mirrors Paper 1, 2, 3 style where relevant.
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A production manager at an automotive plant implements several changes to improve efficiency on the shop floor. These actions are summarized in the table below:
| Action | Description |
|---|---|
| 1 | Broken pallets and unused packaging materials are removed from the workstation. |
| 2 |
The table below provides production data for a component on a manufacturing line using lean principles.
| Floor markings are painted to designate the exact location for incoming component bins. |
| 3 | A standardized visual checklist is posted to ensure all workers perform identical maintenance tasks. |
Which sequence correctly identifies the stages of the 5S lean production methodology represented by these actions?
| Production Stage | Processing Time | Waiting Time |
|---|
| Primary Shaping | 20 minutes | 50 minutes |
| Finishing | 15 minutes | 30 minutes |
| Quality Assurance | 10 minutes | 45 minutes |
| Packing | 5 minutes | 15 minutes |
Based on the data provided, what is the total lead time for the production of a single unit?
A factory uses control charts to track the weight of packaged goods. If the data shows a trend towards the lower tolerance limit, the filling machines are recalibrated before any underweight packages are produced. Which quality management technique is being described?
A boutique guitar manufacturer tracks the duration of various stages in their production cycle to improve efficiency. The data for a specific custom order is provided in the table below.
| Production Stage | Duration (days) |
|---|---|
| Order verification and processing | 1 |
| Material preparation and seasoning | 7 |
| Manual assembly and finishing | 5 |
| Quality inspection and packaging | 2 |
| Shipping and delivery to customer | 4 |
Based on the table, what is the total lead time for this order?
A manufacturing firm uses a specific strategy where production is only initiated once a signal is received from the next stage of the assembly line or from a customer order. The characteristics of this strategy are summarized in the table below.
| System Component | Description |
|---|---|
| Production trigger | Downstream customer demand |
| Stock levels | Low work-in-progress (WIP) |
| Operational goal | Elimination of overproduction |
Which strategy from lean manufacturing is described?
1: Sort; 2: Set in order; 3: Standardize
1: Set in order; 2: Shine; 3: Sustain
1: Sort; 2: Shine; 3: Set in order
1: Standardize; 2: Sort; 3: Sustain
50 minutes
140 minutes
190 minutes
240 minutes
