341 Exam 2, BUAD 342 Exam 2 Final version Also includes Clicker questions from class

Upper limit= 22 Lower limit= 14 Target Value?

(14+22)/2= 18

Target Value on the Control Chart formula

(Lower Limit + Upper Limit)/2

It takes 7 machines 7 minutes to make 7 widgets. How long would it take 100 machines to make 100 widgets? A. 7min B. 1min C. 100min

A. 7min

He was the first to use assembly line in car manufacturing: A. Henry Ford B. Taiichi Ohno C. Pierre Samuel du Pont D. Eliyahu Goldratt

A. Henry Ford

If product/service quality increases, then costs will: A. Increase B. Decrease C. Stay the same D. Cannot tell

A. Increase

If setup/changeover times increase, then lot/batch sizes will likely: A. Increase B. Decrease C. Stay the same D. Cannot tell

A. Increase

Which one of the following statements is TRUE regarding JIT inventory? A. It is the minimum inventory necessary to keep a perfect system running B. It increases if setup costs decrease C. It hides variability D. It exists just in case something goes wrong E. It is minimized with large lot production

A. It is the minimum inventory necessary to keep a perfect system running

Manager noticed they often run out of one flavor or another during operating hours. Manager decided to modify the approach by making small portions of all three flavors and bake them simultaneously. (Dedicate a third of the oven space to each flavor). This new approach is and example of? A. Level scheduling B. Low inventory C. Respect for people D. Continuous improvement

A. Level scheduling

Which chart is percent of damages? A. P Chart B. C Chart C. X-bar Chart D. Range Chart

A. P Chart

Which system tends to have lower throughput time? A. Pull B. Push

A. Pull

Andon Cord means: A. Quality at the source B. Visual signal C. Level scheduling D. Standard work

A. Quality at the source

Service blueprinting focuses on: A. The level of customer-provider interaction B. Value-added vs non-value-added times C. Quality improvement D. Setup time reduction

A. The level of customer-provider interaction

A companys reputation depends on quality of its product: A. True B. False

A. True

Sample size = # of Observations A. True B. False

A. True

Total quality management defines quality by identifying and meeting customers expectations A. True B. False

A. True

Variability is inherent in every process. A. True B. False

A. True

Work cells often are U-shaped to make operator and material movements easier within the cell. A. True B. False

A. True

Value-stream mapping helps to identify: A. Value-added time B. Customer-provider interaction C. Suppliers schedule D. Production quantity

A. Value-added time

The purpose of an xbar chart is to determine whether there has been a: A. change in central tendency B. change in the range within samples C. change in number of defective products D. change in percentage of defective items

A. change in central tendency

Managing quality helps build successful strategies of: A. differentiation, low cost and response B. differentiation, low cost and service C. differentiation, time and service D. differentiation, time and response

A. differentiation, low cost and response

Which of the following refers to prevention costs? A. employee training B. lab worker salaries C. scrap D. returned goods E. all of the above

A. employee training

Which of the following refers to external failure costs? A. returned goods B. rework C. employee training D. quality testing

A. returned goods

A cashier serves 20 people per hours. On average how much time does the cashier spend on one customer? A. 2 min B. 3 min C. 4 min D. 5 min

B. 3 min 60min/20= 3

If throughput rate is 5 units/hr and WIP is 20 units, what is throughput time? A. 100 hours B. 4 hours C. 5 hours D. 20 hours

B. 4 hours 20/5= 4

Daily demand for component is 800 brackets. Workday is 8hours. A container with 3o parts can be manufactured and delivered in 72min. The safety factor is set to 5% of hourly demand. How many Kanbans are needed? A. 4 B. 5 C. 3 D. 26

B. 5 K=(Demand DL+Safety)/Size of container (120+5)/30= 4.16 = 5 Kanbans (Round up, cant have part of Kanban)

Randomly select and weigh 9 boxes and we do this 12 times a day. Repeating it every 30 days. What is sample size? A. 3,240 B. 9 C. 108 D. 12

B. 9

Which chart is # of products? A. P Chart B. C Chart C. X-bar Chart D. Range Chart

B. C Chart

According to lean manufacturing we should have zero inventory. A. True B. False

B. False

Lean principles can only be applied to manufacturing. A. True B. False

B. False

When trying to implement JIT we should quickly drive the inventory level to zero. A. True B. False

B. False

Poka-yokes on Service blueprinting represent: A. Levels of customer-provider interaction B. Potential failure points C. Visual signals to start production D. Areas with high levels of inventory

B. Potential failure points

Which system tends to have higher level of WIP? A. Pull B. Push

B. Push

Which of the following would be a "Common" cause of variation: A. An untrained worker B. Random sources C. Defective raw material D. A machine in need of repair

B. Random sources

On a pareto chart you will see problems represented: A. by level of importance (starting with least important) B. by level of importance (starting with most important) C. alphabetically D. no particular order

B. by level of importance (starting with most important)

Which of the following refers to appraisal costs? A. employee training B. quality testing C. scrap D. loss of customer goodwill E. all of the above

B. quality testing

Which one of the following is not a benefit of JIT implementation? A. cost reduction B. variability increase C. rework reduction D. rapid throughput E. quality improvement

B. variability increase

Daily demand for component is 800 brackets. Workday is 8hours. A container with 3o parts can be manufactured and delivered in 72min. The safety factor is set to 5% of hourly demand. What is hourly demand? A. 800 units B. 50 units C. 100 units D. cannot calculate

C. 100 units 800units/8hr= 100 units

On xbar control chart Upper Limit is 20 and Lower Limit is 10. What is double xbar? A. cant calculate B. 10 C. 15 D. 20

C. 15 20+10= 30 30/2= 15

According to six sigma, how many defects are acceptable in a lot of 1 million units? A. 0 (100% accuracy) B. 2,700 (99.73%) C. 3.4 (99.9997%) D. Any number

C. 3.4 (99.9997%)

Daily demand for component is 800 brackets. Workday is 8hours. A container with 3o parts can be manufactured and delivered in 72min. The safety factor is set to 5% of hourly demand. What is safety level? A. 6 units B. 60 units C. 5 units D. 50 units

C. 5 units 100*.05= 5 units (Safety) (5% of 100)

When implementing heijunka (level scheduling) it is important to: A. Use Kanbans B. Change layouts C. Lower setup/changeover times D. Use value-stream map E. Use service blueprinting

C. Lower setup/changeover times

Which of the following is an example of value-added time? A. Part #1 waiting for Part #2 at the assembly line B. Part #2 is transported to the assembly line C. Part #1 and Part #2 are assembled together on the assembly line D. Finished good is placed in the Warehouse

C. Part #1 and Part #2 are assembled together on the assembly line

He is considered to be the father of Toyota Production system and lean production principles: A. Elji Toyoda B. Kaizen C. Taiichi Ohno D. W Edwards Denim

C. Taiichi Ohno

Line 1: 10 customers per hour and there are 3 people in the line. Line 2: each customer requires 3 min of service and there are 6 people in line. Which line should you join? A. Line 1 B. Line 2 C. They are the same

C. They are the same Line 1.) 60min/10= 6 6*3people= 18 Line 2.) 3min*6people= 18

Which chart is used to analyze Mean? A. P Chart B. C Chart C. X-bar Chart D. Range Chart

C. X-bar Chart

Which chart is used to analyze checkout time? A. P Chart B. C Chart C. X-bar Chart D. Range Chart

C. X-bar Chart

Which of the following refers to internal failure costs? A. quality testing B. returned goods C. machine downtimes D. employee training

C. machine downtimes

Continuous improvement Shewhart/Deming PDCA model means: A. plan, do, check, appraisal B. process, do, check, act C. plan, do, check, act D. plan, do continue, act

C. plan, do, check, act

Which of the following is generally found in most Lean environments? A. push system for purchased parts and a pull system for manufactured parts B. push system for high margin items and a pull system for low margin items C. pull systems D. push or pull system, depending on the rate of demand E. push systems

C. pull systems

According to Philip Crosby: A. quality is more expensive than products B. quality cost only 10% of the product cost C. quality is free

C. quality is free

Definitions of quality fall into these three categories: A. process based, manufacturing based, product based B. user based, engineering based, product based C. user based, manufacturing based, product based D. user based, manufacturing based, service based

C. user based, manufacturing based, product based

means making only what is needed, when it is needed. is an approach of continuous and forced problem solving via a focus on rapid throughput and reduced inventory. materials arrive where they are needed only when they are needed. When good units do not arrive just as needed, a "problem" has been identified. This is the reason this aspect of Lean is so powerful—it focuses attention on problems. By driving out waste and delay, JIT reduces inventory, cuts variability and waste, and improves throughput.

Central to JIT mean?

employee learning and a continuing effort to produce products under ideal conditions with its emphasis on continuous improvement, respect for people, and standard work practices, is particularly suited for assembly lines

Central to TPS is. and emphasis

Daily demand for component is 800 brackets. Workday is 8hours. A container with 3o parts can be manufactured and delivered in 72min. The safety factor is set to 5% of hourly demand. What is demand during lead time? A. 1600 units B. 960 units C. 720 units D. 120 units

D. 120 units 72/60= 1.2 1.2*100= 120 units (Demand DL)

Daily demand for component is 800 brackets. Workday is 8hours. A container with 3o parts can be manufactured and delivered in 72min. The safety factor is set to 5% of hourly demand. What is maximum number of parts in the system? A. 5 B. 120 C. 800 D. 150

D. 150 K*C= Max WIP 5Kabanas*30parts= 150 units

Randomly select and weigh 9 boxes and we do this 12 times a day. Repeating it every 30 days. How many samples are there after 30 days? A. 108 B. 270 C. 30 D. 360

D. 360 30*12= 360

Each control chart has: A. Upper control limit B. Lower control limit C. Target Value D. All of the above

D. All of the above

Which Lean principle can be used to lower inventory level and shorten throughput time? A. Implement Pull B. Lower the batch size C. Implement group technology D. All of the above

D. All of the above

The Pull system is enabled by using: A. Small batch sizes B. Poka-yokes C. Standardise tooling D. Kanbans

D. Kanbans

Which step of the six sigma DMAIC process entails collecting data? A. Analyze B. Control C. Define D. Measure E. Improve

D. Measure

Group technology means all of these EXCEPT? A. Group similar products into families B. Dedicate a work cell to each product family C. Set up machines/processes according to product family process flow D. Place similar equipments/processes in dedicated departments

D. Place similar equipments/processes in dedicated departments

Lowering batch size is beneficial for all EXCEPT? A. Smooth, stable flow B. Shorter throughput time C. Lower WIP D. Preventive maintenance

D. Preventive maintenance

Which chart is used to analyze checkout variability? A. P Chart B. C Chart C. X-bar Chart D. Range Chart

D. Range Chart

To make an ice cream sundae, take one waffle bowl, place 2 cups of vanilla ice cream, drizzle with 3 tbs hot fudge, scatter 1/2 cup walnuts on it, top with 1 cherry. This is an example of? A. Setup time reduction B. Continuous improvement C. Batch size reduction D. Standard work

D. Standard work

Cause and effect diagrams are also called: A. ishkawa B. fishbone C. 4M D. all of the above

D. all of the above

On xbar control chart Upper Limit is 20 and Lower Limit is 10 what is Rbar? A. 10 B. 5 C. 20 D. cant calculate

D. cant calculate

supply the customer with exactly what the customer wants when the customer wants it, without waste, through continuous improvement

Define Lean Operations

Number of kabanas formula

Demand during lead time+Safety stock/Size of container

Lead time for cakes is 2 days with daily demand of 4 cakes and a safety stock of 1/2 day. Each container holds 2 cakes. What is the correct number of kanbans? A. 10 B. 25 C. 4 D. 1 E. 5

E. 5 Daily demand(4)*Lead time(2)= 8 Daily demand (4)* Safety(.5)= 2 8+2/2= 5 kabanas

To lower setup times all of these are beneficial activities EXCEPT? A. Separate setup into preparation and actual setup B. Move materials closer C. Standardize tooling D. Standardize work procedure E. All of them are beneficial

E. All of them are beneficial

All of these are types of waste EXCEPT: A. Overproduction B. Overprocessing C. Waiting D. Defects E. Quality

E. Quality

Total quality management elements are: A. continuous improvement B. six sigma C. employee empowerment D. benchmarking E. all of the above

E. all of the above

Examples of Lean in Healthcare are: A. Clearly identify who's responsible for what procedure. B. Use visual signals to trigger work and next steps. C. Standardize how each procedure would be precisely carried out. D. Naming a person in charge of process improvement. E. Redesign process through experimentation and simulation F. All of the above

F. All of the above

According to lean production all of these are correct actions EXCEPT? A. Eliminate waste B. Produce only whats needed on a given day C. Manage flow with pull instead of push D. Lower batch sizes E. Lower inventory level F. Produce in anticipation of demand

F. Produce in anticipation of demand

Total quality management tools include: A. check sheets B. scatter diagrams C. cause and effect diagrams D. pareto chart E. statistical process control F. all of the above

F. all of the above

Ideal conditions exist only when management brings facilities, machines, and people together to add value without waste. Waste undermines productivity by diverting resources to excess inventory, unnecessary processing, and poor quality. Respect for people, extensive training, cross-training, and standard work practices of empowered employees focusing on driving out waste are fundamental to TPS.

Ideal conditions are keen for TPS to allow for employee learning and continuous effort to produce products. Hence how do these ideal conditions exist or come about

finding and eliminating problems because problems are easy to find in a system that eliminates the slack that inventory generates. When excess inventory is eliminated, shortcomings related to quality, layout, scheduling, and supplier performance become immediately evident—as does excess production. low inventory brings to light potential problems

JIT provides an excellent vehicle for

Formula for LCL r ?

LCL= D3 * Rbar D3 is given in chart

Formula for LCL x ?

LCL= x double bar - A2 * Rbar A2 will be given in chart

the knowledge and capability of employees to build processes that improve productivity and lead to world-class operations

Lean operations, including JIT and TPS, as approaches to continuous improvement. All three approaches, in their own way, strive to increase

WIP = THt x THr, where WIP - represents amount of work in process THt - is the throughput time (i.e., time in system) THr - is the throughput rate Defines the output rate that a process is expected to produce over a period of time (units/time) Represents a measure of process capacity Equals the inverse of the process time of a station simply put it is wip= throughput * throughput rate

Little's Law

Plane was late Poor connections

Machinery examples

Not enough traffic police Need more attendants

Manpower examples

Poor or no food Tickets too expensive

Material examples

Seats are too close Need larger restrooms

Method examples

a single product moving through all stages of production one at a time

One Piece Flow

A set of integrated activities designed to Achieve high-volume production, while Minimizing waste in the production process, e.g., Reduce inventories of raw materials, WIP and finished products (overproduction) Reduce defects and rework due to poor quality Reduce waiting due to resource or part unavailability Reduce unnecessary transportation and motion Reduce overprocessing - work that doesn't add value

Overall lean production is and what does it do

The main objective of Statistical Process Control is?

Signal presence of special case variation

How do you find rbar?

Take the average of Range. Add up all range values and divide by how many. Ex: 5+5+4+1+2+1= 18 18/6= 3

The American society for quality defines quality as?

The totality of features and characteristics of a product or service that bears on its ability to satisfy stated or implied needs

Formula for UCL r ?

UCL= D4 * Rbar D4 is given in chart

Formula for UCL x ?

UCL= x double bar + A2 * Rbar A2 will be given in chart

just-in-time production

What does JIT stand for?

Lean, JIT, and TPS systems sustain competitive advantage and result in increased overall returns

When implemented as a comprehensive manufacturing strategy (lean, jit, tps) what happens

How do you find x double bar?

You take the average of x bar (mean). Add up all mean values and divide by how many.

workflow initiated by the "pull" of the customer's order

lean operations are driven by

eliminate waste, remove variability, and improve throughput.

operations managers address three issues that are fundamental to operations improvement:

A special flowchart of a service process that shows which steps have high customer contact

service blueprint

JIT TPS

two lean techniques

Map processes and identify value-added and non-value-added activities

value chain mapping