mgmt test 2

What two tag colors are used in the process experiment at the Bearington plant?

green and red

product control

inspecting a product at the end of a process

Lean Principles

1. Value 2. Value Stream 3. Flow 4. Pull 5. Perfection

What is the lead time (in minutes, order to delivery) for 300 airplanes (Batch size = 1)? Round your answer to the nearest minute. Assumption: Production for this order starts as soon as the order is received, and the first unit must start at the beginning of the process (Step 1).

126

What is the lead time (in minutes, order to delivery) for 300 aircraft (assume batch size = 10)? Round your answer to the nearest minute. Assumption: Production for this order starts as soon as the order is received, and the first batch must start at the beginning of the process (Step 1).

131

What is the required takt time (in seconds) to meet the increased customer demand (1,920 airplanes/day)? Enter number of seconds only.

15

What is the cycle time (in seconds) of the paper airplane production process? Enter number of seconds only. Step 1 = 6 seconds/aircraft Step 2 = 15 seconds/aircraft Step 3 = 15 seconds/aircraft Step 4 = 25 seconds/aircraft

25

The Bearington plant set a new plant record by shipping how many orders by Friday afternoon?

57 orders shipped

What is the throughput time (in seconds) for a single airplane? Enter number of seconds only.

61

lean thinking

socio-technical operations management system by which the main objective is to eliminate waste and maximize value (to the customer).

The continuous process improvement cycle consists of four steps. Please use the drop down menu to identify the correct step in the cycle for each continuous improvement action: Do - make the improvement. Plan - identify a process improvement. Act - implement the improvement into the process. Check - examine feedback and adjust improvement as necessary.

do- 2 plan-1 act-4 check-3

What are the four operational performance objectives we have discussed in class?

flexibility, cost, delivery (speed), quality

When Alex challenges his children to come up with a solution to keep everyone together in line on a hike when you can't move Herbie, his daughter Sharon suggests...

using a drum

When you make use of a resource in a way that moves the system toward the goal, Jonah calls this...

utilization

In a Lean organization, who is responsible for problem solving?

all employees

assignable variation

(aka special variation or signal variation) this is variability that is not inherent to the system, but is the result of some change in the system and can usually be traced to a specific cost

2 ways to deal with assignable variation

-Identify the root cause and make process changes to eliminate the cause •If it cannot be eliminated, allow the process to accommodate it

Which are root causes of the bullwhip effect? (select all that apply)

-black box observing patterns -lag time -no communication

Refer to the "Lean as a Universal Model of Excellence" article. Initial lean implementation often requires a shift in organizational culture toward which of the following outcomes (select all that apply)?

-heightened collaboration - cross-functional trust -empowerment

The management team ultimately creates a practical theory to replicate their success in other parts of UniCo. Please use the drop down menu to put the parts of the emerging theory in correct order: [ Select ] ["", "Step 1"] : Identify the system's constraint(s). [ Select ] ["", "Step 2"] : Decide how to exploit the constraint(s) Step 3 : Subordinate everything to the above decision(s). [ Select ] ["", "Step 4"] : Elevate the system's constraint(s). [ Select ] ["", "Step 5"] : Go back to Step 1. Do not allow inertia to cause a system's constraint.

Answer 1:Step 1 Answer 2:Step 2 Answer 3:Step 3 Answer 4:Step 4 Answer 5:Step 5

How does Jonah define a bottleneck?

Any resource whose capacity is equal to or less than the demand placed on it.

In the modern view of quality management, who is responsible for quality?

all employees

According to Jonah, an hour lost at a bottleneck is __________.

an hour lost for the whole system.

Refer to the "Lean as a Universal Model of Excellence" article. In the early days of Toyota, what was Taiichi Ohno's means of controlling cost?

Elimination of waste

In the "Lean Thinking Explained by Eating Pizza" video, rotten tomatoes represented what type of waste?

Excess inventory

The proposed distribution system whereby Barilla's logistics organization (as opposed to its distributors) would specify "appropriate" delivery quantities was called:

JIT

Which one of the following statements best describes the Bearington plant strategy prior to Jonah?

Maintain efficiencies by building inventory

Refer to the "Lean as a Universal Model of Excellence" article. Kiichiro Toyoda, son of Toyota's founder, developed just-in-time inventory management. He also purchased simple and flexible manufacturing equipment, which allowed for quick setups and small batches sizes. What did this approach allow Toyota to do?

Make a variety of vehicles in low volumes to match with demand

In the "Lean Thinking Explained by Eating Pizza" video, unused dough represented what type of waste?

Overproduction

at what point in the process does Jonah recommend Quality Control occur?

Quality Control should happen before a bottle-neck.

How do you think sales promotions affected Barilla's ability to match supply with demand?

Sales promotions made it more difficult to match supply with demand.

who is Ralph Nakamura?

The data processing manager at the Bearington Plant

What is one thing the team at the Bearington plant did to reduce bottlenecks at the NCX-10?

They worked with the union to keep the NCX-10 active during breaks.

n class, we have identified and defined 7 categories of waste. Match the type of waste with its definition. Transportation Inventory Motion Waiting Overprocessing Overproduction Defects

Transportation-Workflow is neither direct nor smooth. inventory-Inventory in excess of immediate needs. motion-Non-value-adding movement by workers waiting-Inefficient work sequence. overprocessing- Work that adds no value. overproduction-Producing ahead of demand or in excess of demand. defects- Rework, scrap, returns.

Who gets promoted to division vice president when Bill Peach moves up to corporate?

alex rogo

out of control

a process is out of control when it exhibits assignable variation. Process control allows us to detect this change and eliminate or incorporate it.

in control

a process that exhibits only common variation is said to be in control or stable.

Statistical process control

a set of statistical tools that allows us to monitor a process, see if it is stable, and distinguish randomness from variation that we can track down and eliminate

Barilla's marketing and sales strategy was based upon a combination of __________ and __________.

advertising and promotions

Consider an aircraft manufacturing process. In order to ensure structural integrity of each aircraft's wings, operators are required to inspect a sample of aircraft wing dimensions. This inspection ensures the wing fabrication process is operating within given specifications. The cost of quality incurred to inspect the wings is an example of:

appraisal cost

Jonah teaches that activating a resource and utilizing a resource...

are not the same thing

Refer to the Taco Bear control chart results, the process exhibits ________ variation.

assignable

Who becomes the new plant manager at the Bearington Plant?

bob

The wild demand fluctuations Barilla was experiencing represent which phenomenon?

bullwhip effect

reduce variability

by improving product or process design, inputs, or process execution - this will reduce the probability that unexpected variance will lead to quality problems.

detect variability

by measuring process steps and establishing systems to flag when a process exceeds its set bounds - goal is to detect quality problems before they result in flawed products.

Random variation that inherently exists in every system is:

common variation

The historical view of quality holds the assumption that when something goes wrong, it is the fault of the individual on duty at the failure point. This assumption is also prevalent in which type of strategy (from the Operations Integrity module):

compliance

Represents adherence to design specifications:

conformance quality

internal failure costs-pc

cost of recovering from defects within the production process.

Control Costs

costs an organization incurs to prevent, manage, and maintain the quality of its products or services.•Sub-dimensions: prevention costs and appraisal costs•Examples: process design, process control, product inspections, customer surveys

Prevention Costs-cc

costs associated with tasks intended to prevent defects from occurring.

external failure costs-pc

costs incurred when a defect reaches the customer.

appraisal costs-cc

costs of monitoring, inspecting, and testing to detect quality problems at various points in a process.

In the "Lean Thinking Explained by Eating Pizza" video, when the pizza restaurant owner faces price competition, what should be his first step?

cut waste

quality

degree to which a product or service meets or exceeds customers' needs and expectations

lean thinking is viewed as a system focused on creating customer _____.

demand

The two objectives of process control are to

detect and reduce

What primary type of waste did the current distribution system result in?

excess inventory

Which three of the 7 Deadly Wastes (according to Lean Thinking) were most prevalent during Round 1 of the (paper) airplane production simulation? Hint: Operators were given the order to achieve 100% efficiency during this round.

excess inventory, excess motion, overproduction

Customer deaths caused by the listeria outbreak represent the highest form of what type of cost of quality?

external failure cost

Lean principles can only be applied in manufacturing.

false

Multiple issues had stalled the implementation of the new distribution system, to include:

internal resistance from Barilla's own sales and marketing organizations customers' reluctance to provide detailed sales data customers' unwillingness to give up authority to place orders (all of the above)

Supply Chain Management

is the management of relationships in the network of organizations, from end customer through original suppliers, using key cross-functional business processes to create value for customers and other stakeholders.

Below are several labels describing the time a piece of material spends inside the plant from its entry as a raw material until its exit as a finished product. I. Setup time II. Process time III. Static time IV. Queue time V. Wait time

iv and v

Disney theme parks often try to make waiting for rides as pleasant as possible. According to your reading, this service attribute addresses which dimension of quality?

lead time

Jonah and the team visit the quality control area of the plant where they find rejected products that did not pass quality inspection. From what lot number were they studying rejects?

lot 109

process control

monitoring individual process steps to ensure the process is running the way we want it to.

Customer demand has increased to 1,920 airplanes/day. Can the current system, without improvements, meet the increased demand?

no

If we cross-train all employees, can we meet the increased demand (1,920 airplanes/day)?

no

How much dry product inventory did each Barilla central distribution center (CDC) hold?

one month

Refer to your slides and "Managing Quality" reading to answer the following question. Although conformance is ultimately a measurement of the ________, the best way to achieve it is to monitor and adjust the process.

output

Most distributors used simple _________ inventory systems.

periodic-review

Cogswell Cogs is experiencing a higher than acceptable number of defects in its newest product, the "iCog." In an attempt to reduce the number of defects, George (the production supervisor) implemented a training program for Cogswell's "iCog" production line workers. The cost of quality incurred to train the employees is an example of:

prevention cost

capable

process that is capable consistently meets design specifications (referred to as tolerances) or customer specifications. A process that is in control may not be capable if its common variation is too great.

A production system that uses customer demand as the primary driver for production planning is a ____ system.

pull

What type of production system was operating during Round 2?

pull

which key production decision did the Bearington team implement to make one thousand Model 12's for Bucky Burnside?

reduced batch sizes by half

You recently purchased a new bicycle. Two months after the purchase of the bike, the gears start to slip regularly and you have to take it to the bike shop for repair. Which quality dimension does the gear issue represent?

reliability

Refer to the "Intro to Quality Management" slides. Quality failure costs _____ rapidly as a product or service moves through the production process.

rise

Quality management

set of activities that an organization performs to improve and maintain the quality of its products and services.

Please place a check by the name of Alex and Julie's two children.

sharon and david

Match each 5S step with its definition. Sort Straighten / Set in Order Shine Standardize Sustain

sort- Only keep needed items in the work area. straighten-Keep items organized so they can be found quickly. shine-Clean and fix up the selected area. standardize-Develop guidelines for using the selected area. sustain-Maintain the gains accomplished.

While working with Pete and the robots, Alex realizes that the maximum deviation of a preceding operation (Pete) becomes the _____________ of a subsequent operation (the robots).

starting point

Which process step do we need to improve to increase system capacity?

step 4

Performance Quality

the ability of a product or service to excel along one or more performance dimensions ("attributes" or "features")

failure costs

the costs an organization experiences due to poor quality.•Sub-dimensions: internal failure costs and external failure costs•Examples: rework, scrap, customer returns, product recalls, lost sales

conformance quality

the degree to which a product or service conforms to the specifications of its design and achieves its specified performance

Variability

the enemy of quality control Variability inherently occurs in process:•Inputs (e.g., raw materials)•Parameters (e.g., machine settings, operating procedures)•Execution (e.g., different machines or employees with different skill levels)

common variation random

this is the random variation (also known as natural variation or noise variation) that inherently exists in every system

What does Hilton Smyth agree that the goal of the Bearington Plant is?

to reduce costs

Conformance quality can be free because it reduces total cost.

true

Despite some seasonality for a few special types of pasta, Italy's total pasta consumption was relatively consistent throughout the year.

true

Lean is an operational excellence strategy that enables people, and organizations, to change for the better.

true

The lean principles are represented as a cycle of actions, with the ultimate goal to create customer value. Please use the drop down menu to identify the correct number for each principle: Value stream - organize value creating steps of the process in the best way. Value - make sure the process meets customer needs. Flow - conduct value creating steps without interruption. Perfection - pursue continuous process improvement. Pull - ensure process steps are driven by customer demand.

value stream- p2 value-p1 flow-p3 perfection-p5 pull-p4

What is the "enemy" of quality control? Choose the best answer as depicted in your slides or reading.

variability

Lean Thinking entails the persistent pursuit and elimination of ________.

waste/ muda

Customer demand = 960 airplanes/day Can the production system currently meet demand? Assume one 8-hour shift/day, and system is in steady state. Hint: Calculate the system's daily capacity.

yes

what scm is not

•It is not another name for logistics. •It is not another name for purchasing (or procurement). •It is not another name for operations. •It is not simply a combination of logistics, purchasing and operations.

supply chain

•Network of organizations: Raw materials providers, Manufacturers, Wholesalers and distributors, Retailers, Service Providers Connected by forward and reverse flows of goods, information, and enabling resources •All interested in creating value for the ultimate customer