Chapter 7
10. An employee who will not help a customer because "it is not my job" violates the JIT belief of a) Simplicity b) A broad view of operations c) Continuous improvement d) Visibility e) Pull production
A broad view of operations
55. Regular inspections and maintenance designed to keep a machine operational is __________ maintenance. a) Preventive b) Breakdown c) Unscheduled d) Emergency e) Unnecessary
Ans: a Section Ref: Total Quality Management Level: moderate
74. Which of the following is not considered to be a key element of JIT supplier relationships? a) suppliers viewed as internal factory b) use of single-source suppliers c) long-term supplier relationships developed d) suppliers locate near customer e) cost and information sharing
Ans: a Section Ref: Benefits of JIT Level: hard
22. JIT is a __________ system. a) Pull b) Push c) Lead time d) Preventive maintenance e) Closed
Ans: a Section Ref: Elements of JIT Level: easy
26. According to JIT, __________ is carried to cover up a wide variety of problems, such as poor quality, demand uncertainty, and slow delivery. a) Inventory b) Excess capacity c) A group of back-up workers d) Spare equipment e) Insurance
Ans: a Section Ref: Elements of JIT Level: moderate
33. JIT believes in developing __________ relationships with suppliers. a) Long-term b) Adversarial c) Arms-length d) Temporary e) Distant
Ans: a Section Ref: Elements of JIT Level: moderate
49. One aspect of flexible resources is a) Use of multifunction workers b) Relying on special equipment c) Use of overtime d) Leasing, rather than buying, equipment e) Variable work schedules
Ans: a Section Ref: Just-In-Time Manufacturing Level: hard
38. In JIT a Kanban card is used to signal a) The need for more parts b) A supplier needs assistance c) A worker is overloaded d) A machine is ready for preventive maintenance e) Management is inspecting operations
Ans: a Section Ref: Just-In-Time Manufacturing Level: moderate
42. It the goal is to reduce the amount of inventory in the system, the number of Kanban cards should a) Be decreased b) Be increased c) Remain the same d) Be calculated by formula e) Remain the same, but container size should be increased
Ans: a Section Ref: Just-In-Time Manufacturing Level: moderate
71. Which of the following is not a good approach for suppliers who are providing JIT services to manufacturers? a) Use the "push system" for deliveries b) Locate near their customers c) Have small warehouses near the manufacturing plant d) Use standardized containers e) Join together with other suppliers to help each other make small deliveries
Ans: a Section Ref: Respect for People Level: easy
70. The benefits of long-term relationships with a small number of suppliers include all of the following except a) Always getting the lowest price b) Focus on improving process controls c) Greater accountability d) Develop stable delivery schedules e) Eliminate paperwork
Ans: a Section Ref: Respect for People Level: moderate
30. The objective of quality at the source is not only to identify a quality problem, but also to a) Determine its extent b) Uncover its root cause c) Rate its seriousness d) Place blame e) Categorize it
Ans: b Section Ref: Elements of JIT Level: hard
21. JIT relies on a ______ that withdraws parts for a previous work cell and moves them to the next. a) Information technology system b) coordination system c) six sigma system d) quality circle system e) transportation system
Ans: b Section Ref: Elements of JIT Level: moderate
40. The number of kanbans or containers needed at a workstation is dependent on all except which of the following? a) the demand rate b) the number of workers c) the size of the container d) the lead time e) the safety stock level
Ans: b Section Ref: Just-In-Time Manufacturing Level: moderate
41. The system of Kanbans used to coordinate delivery of goods by suppliers can include all of the following except a) Filled containers delivered by the supplier b) Purchase approvals by the production manager c) Mail boxes for each supplier d) Empty containers with a Kanban e) Bar-coded Kanbans
Ans: b Section Ref: Just-In-Time Manufacturing Level: moderate
47. External setups a) Are the same as single setup b) Can be done while the machine is running c) Are undesirable for small lot production d) Are often contracted out e) Are more common than internal setups in traditional manufacturing systems
Ans: b Section Ref: Just-In-Time Manufacturing Level: moderate
48. Uniform plant loading involves a) Large lots produced over several days b) Making the same mix of products every day in small quantities c) Large amounts of inventory d) Making large changes in production to respond to changes in demand e) Spreading production uniformly over several plants
Ans: b Section Ref: Just-In-Time Manufacturing Level: moderate
65. Which of the following is not a role of JIT management? a) creating a JIT culture b) cost and information sharing c) serving as coaches and facilitators d) developing an incentive system e) ensuring multifunctional training occurs
Ans: b Section Ref: Respect for People Level: easy
62. JIT production workers a) Keep data to themselves b) Participate in team problem-solving activities c) Do not understand data d) Never use data e) Rely on others to do data analysis
Ans: b Section Ref: Respect for People Level: moderate
68. With JIT a company's relationship with its suppliers includes a) Competitive bidding b) Being in partnership with them c) Buying parts from the cheapest supplier d) Short-term relationships e) Having as many suppliers as possible
Ans: b Section Ref: Respect for People Level: moderate
54. Poka-yoke means a) Using color coding b) Foolproofing c) Using process control charts d) Preventive maintenance e) Undercapacity scheduling
Ans: b Section Ref: Total Quality Management Level: moderate
58. Something you would not expect to see in a just-in-time work environment is a) Order b) Clutter c) Ample space d) Tools in their place e) Cleanliness
Ans: b Section Ref: Total Quality Management Level: moderate
23. JIT manufacturing cannot succeed if __________costs are too high. a) Variable b) Fixed c) Set-up d) Depreciation e) Marginal
Ans: c Section Ref: Elements of JIT Level: moderate
32. In JIT the workforce is viewed as a) another resource to be managed b) another contractual obligation c) a long-term asset d) a short term asset e) an asset that must be closely managed
Ans: c Section Ref: Elements of JIT Level: moderate
73. In making specific changes to JIT manufacturing, which of the following steps should come first? a) reduce lot sizes and lead times b) switch to pull production c) reorganize workplace d) reduce setup times e) implement layout changes
Ans: c Section Ref: Implementing JIT Level: hard
46. What is the term for an adjustment of a machine after making one product type so that production can begin for another product type? a) Level assembly schedule b) Group technology c) Setup d) Cycle time e) Automation
Ans: c Section Ref: Just-In-Time Manufacturing Level: easy
35. Traditional manufacturing operations are based on the assumption that a) Overproduction is disastrous b) Nice guys finish last c) It is better to anticipate future requirements and plan for them d) If you manufacture it, demand will increase e) Inventory has no value
Ans: c Section Ref: Just-In-Time Manufacturing Level: hard
37. With JIT there are two types of Kanban cards, production Kanban and __________ Kanban. a) Buffer b) Transaction c) Withdrawal d) Logistics e) Sales
Ans: c Section Ref: Just-In-Time Manufacturing Level: hard
39. Without kanbans, the withdrawal and production of materials a) can continue in a reduced manner b) will not be well coordinated c) cannot take place d) would continue based on historical needs e) would continue based on forecasted needs
Ans: c Section Ref: Just-In-Time Manufacturing Level: moderate
61. JIT production workers are expected to a) Cover up quality problems b) Ignore data c) Take responsibility in getting to the root cause of quality problems d) Blame problems on someone else e) Have a poor attitude about quality
Ans: c Section Ref: Respect for People Level: moderate
51. Quality in just-in-time is centered on building quality into the a) Product b) Maintenance of equipment c) Process d) Distribution system e) Workforce
Ans: c Section Ref: Total Quality Management Level: hard
52. Quality problems in manufacturing can come from many sources, including all of the following except a) Customer needs are not incorporated into the product design b) Low quality materials from suppliers c) Product specifications being ignored d) Equipment problems from design of the production process e) Operator error
Ans: c Section Ref: Total Quality Management Level: hard
56. According to JIT, workers should perform a) system specification development b) as directed by the supervisor c) routine preventive maintenance activities d) poka-yoke designs e) quality program development
Ans: c Section Ref: Total Quality Management Level: moderate
59. Just-in-time organizations rely on employees to a) Do what their boss tells them to do b) Dress differently every day c) Work together d) File grievances e) Be adversarial toward management
Ans: c Section Ref: Total Quality Management Level: moderate
28. What must happen before it is possible to operate successfully with JIT? a) Inventory space must be eliminated b) Inventories must be reduced rapidly c) Problems must be uncovered d) Problems must be solved e) Setup times must be increased
Ans: d Section Ref: Elements of JIT Level: hard
24. The ultimate goal of JIT is to produce products in a lot size of a) 100 or fewer b) N = (DT(1+X))/C c) The inverse of the carrying cost d) One e) The capacity of the factory
Ans: d Section Ref: Elements of JIT Level: moderate
25. Unlike JIT traditional quality control systems use a) quality circles b) quality plans c) control charts d) acceptable quality levels e) quality applications
Ans: d Section Ref: Elements of JIT Level: moderate
29. An important TQM concept is that quality is defined by the a) Quality control group b) Marketing department c) Board of directors d) Customer e) Auditors
Ans: d Section Ref: Elements of JIT Level: moderate
31. JIT considers __________ to be a company's most precious resource. a) Capital b) Productive equipment c) Information d) People e) Vision
Ans: d Section Ref: Elements of JIT Level: moderate
34. __________ are groups of workers who are responsible for every aspect of their business. a) Focus teams b) Staff departments c) Partnerships d) Self-managed teams e) Negotiators
Ans: d Section Ref: Elements of JIT Level: moderate
72. The challenge for service operations is that they have to synchronize their __________ with demand. a) accounting b) finance c) marketing d) production e) information systems
Ans: d Section Ref: JIT In Services Level: easy
64. Which of the following is not a characteristic of bottom-round management? a) Consensus management by committees or teams b) Participation in quality circles c) Decision making starts with discussion at the bottom level d) Lack of consensus e) Employees volunteering to help solve quality problems
Ans: d Section Ref: Respect for People Level: easy
63. The role of production employees in JIT includes all of the following except a) Be actively engaged in improving the production process b) Monitor quality c) Record data d) Follow clearly defined and limiting work rules e) Act on the information they have
Ans: d Section Ref: Respect for People Level: moderate
69. With regard to suppliers, JIT typically requires a) Delivery of large lots at regular intervals b) Buyer inspection of incoming goods and materials c) Multiple sources from which to purchase d) Information sharing e) Buying parts from the cheapest supplier
Ans: d Section Ref: Respect for People Level: moderate
75. One of the greatest benefits of JIT would be a) increasing waste and improving responsiveness b) longer lead times and increased productivity c) decreased machine utilization and improved quality d) competing based on schedules e) eliminating waste, improving responsiveness and competing based on time
Ans: e Section Ref: Benefits of JIT Level: hard
27. According to JIT, by eliminating inventory we can clearly identify __________ and work on eliminating them. a) Obsolete products b) Malfunctioning machines c) Grievances d) Product imperfections e) Problems
Ans: e Section Ref: Elements of JIT Level: easy
36. JIT uses a pull system where communication starts with either the customer or with the _________ work station in the production line. a) First b) Bottleneck c) Dominant d) Most expensive e) Last
Ans: e Section Ref: Just-In-Time Manufacturing Level: easy
45. Small lot production a) Increases inventory b) Decreases flexibility c) Reduces setup d) Increases excess processing e) Shortens lead time
Ans: e Section Ref: Just-In-Time Manufacturing Level: hard
50. The advantages of cell manufacturing using a U-shaped cell include all of the following except a) Production efficiency with flexibility to produce a variety of parts b) Easy reach and flexibility for workers c) Higher worker satisfaction d) No special material handling e) Longer setup times
Ans: e Section Ref: Just-In-Time Manufacturing Level: moderate
66. In Japan, lifetime employment a) Is a recent trend b) Has had little impact c) Is an ideal that is never achieved d) Is true for everyone e) Comprises a relatively small percentage of the total work force today
Ans: e Section Ref: Respect for People Level: hard
60. Just-in-time relies on __________ worker skills, meaning the ability of workers to perform many different tasks on many different machines. a) Natural b) Verbal c) Intuitive d) Manual e) Cross functional
Ans: e Section Ref: Respect for People Level: moderate
67. In a JIT environment, workers need to a) Protect themselves from their boss's whims b) Be prepared to be reprimanded c) Keep their ideas to themselves d) Always work in pairs e) Feel secure in their jobs
Ans: e Section Ref: Respect for People Level: moderate
57. Which of the following is not characteristic of preventive maintenance in JIT systems? a) Keeping machines operational b) Regular inspections of machines c) Workers helping to maintain their own equipment d) Operating machines properly e) Perceiving breakdowns as an opportunity for continuous quality improvement
Ans: e Section Ref: Total Quality Management Level: hard
53. What is the term that means giving workers authority to stop the production line when quality problems are encountered? a) Automation b) Kaizen c) Muda d) Poka-yoke e) Jidoka
Ans: e Section Ref: Total Quality Management Level: moderate
2. JIT considers waste anything that a) Fits in a waste basket b) Reduces production capacity c) Has been discarded d) Cannot be recycled e) Does not add value
Does not add value
7. The central belief of the JIT philosophy is a) Quality must be emphasized b) Use of Kanban c) Elimination of waste d) Minimize inventory e) Save money
Elimination of waste
8. Which of the following is characteristic of the JIT philosophy? a) Inventories are an asset b) Lot sizes are optimized by formula c) Tolerate some scrap d) Elimination of waste e) Rigidity
Elimination of waste
15. Being able to keep costs low while changing the volume of production is an example of a) Simplicity b) Flexibility c) Visibility d) Continuous improvement e) Total quality management
Flexibility
4. The philosophy of JIT a) Originated in Japan b) Was operational at Henry Ford's complex in 1920's c) Is a production planning system d) Has received little attention in the US e) Focuses on direct control of worker activities by management
Originated in Japan
9. Beliefs that help define the JIT philosophy include all of the following except a) Simplicity b) Visibility c) Flexibility d) Push production e) Continuous improvement
Push production
16. Three basic elements work together to complete a JIT system: just-in-time manufacturing, total quality management, and a) Quality circles b) Pull production c) Minimizing inventory d) Respect for people e) Full utilization of capacity
Respect for people
20. For the current month using JIT a) The same amount of each product is produced in the same order each day b) Production matches that of last month c) Lot sizes are varied week-to-week d) Production differs greatly from day to day e) Production is primarily for next month's sales
The same amount of each product is produced in the same order each day
1. JIT is applies to a) only the manufacturing organization b) only the service organization c) both the manufacturing and service organizations d) only the production portion of manufacturing and service organizations e) all of the organization except the marketing division
both the manufacturing and service organizations
12. Kaizen is a Japanese term referring to __________________________. a) just-in-time production b) continuous improvement c) employee involvement d) concurrent engineering e) simplicity
continuous improvement
19. The manufacturing process in JIT starts with the a) final assembly schedule b) schedules for individual machines c) vendor deliveries d) prioritization of lots e) forward scheduling
final assembly schedule
3. JIT can be traced back to the early 1900's but no one can argue that the philosophy gained worldwide prominence a) at the close of WWII b) in the 1950s c) in the 1960s d) in the 1970s e) in the 1980s
in the 1970s
13. An improvement tool that utilizes cross-functional teams to plan and deliver improvements to specific processes during two- or three-day marathon sessions is called a ___________________. a) kanban blitz b) cross-functional blitz c) short-term blitz d) JIT blitz e) kaizen blitz
kaizen blitz
5. The broad view of JIT is now often termed __________________________. a) vendor-managed inventory b) business process reengineering c) lean production d) cycle time management e) e-distribution
lean production
17. JIT is often mistakenly assumed to a) refer to the final assembly schedule only b) dictate the product standards specification c) refer to only just-in-time manufacturing d) be a core element of ISO 9000 requirements e) be driven by the finance department long range spending plan
refer to only just-in-time manufacturing
11. JIT was based on the need for a) survival b) waste elimination c) better working conditions d) consistent application of policies e) consistent supplier performance
survival
6. In the broad view of the organization everyone should have a) the same job duration b) the same retirement plan c) the same job description d) the same view of serving the customer e) a narrow view of the organization that includes only their assigned tasks
the same view of serving the customer
18. By focusing on __________ processes, JIT is able to achieve high-volume production of high-quality, low-cost products. a) downstream b) upstream c) change-over d) gateway e) value-added
value-added
14. JIT flexibility refers to a) ability to modify sales figures b) correct the bull whip effect c) increase or decrease supplier deliveries on short notice d) workers being able to perform many different tasks e) managers being able to shift positions easy
workers being able to perform many different tasks
