MSSC test 4

When documentation for product/process compliance with customer requirements is complete, the customer and all involved parties must __________. - "Sign-off" the documentation - Submit the documentation to a lawyer - Submit the documentation to the supervisor for approval - Contact OSHA regarding the next course of action

- "Sign-off" the documentation

The box certificate shown has an edge crush limit of __________. - 75 inches - 65 pounds - 32 pounds/inch - 64 inch/pounds

- 32 pounds/inch

Standardization is put into place by standardizing work and what other method? - Increasing production - 5S process - Organizing the standards - Sorting and Straightening

- 5S process

A supervisor should be contacted for assistance when __________. - The marketing department issues a new product brochure - A production employee has no trouble understanding the customer specs - A production employee is having trouble making the product to spec - A competitor introduces a new product line

- A production employee is having trouble making the product to spec

What is the definition of value-added activities? - Activity that increases the cost or value to the product - Activity that adds what the customer wants - Activity that adds processes to production - Activity that increases the purpose of the product

- Activity that adds what the customer wants

One of the results of Straighten is to __________. - Free up space - Arrange items in the order of their use - Reduce the time to locate tools - Reduce clutter in the work area

- Arrange items in the order of their use

When a worker is asked to lift a part or product repeatedly throughout the day, the company should __________. - Provide a step ladder - Do nothing, it is not that heavy - Arrange to move the part to a more comfortable working height - Always be sure that the person is tall enough to do the task

- Arrange to move the part to a more comfortable working height

As part of a process of continuous improvement, companies use __________ to set goals to strive towards. - Benchmarks - Statistical Process Control - Pareto charts - JIT

- Benchmarks

In a production process, the time required to create a finished product is determined by the slowest processing station. The slowest station, often called a __________, therefore limits the maximum rate of production. - Y factor - Bottleneck - Cpk - Funnel point

- Bottleneck

5S is a lean manufacturing technique that focuses on creating a __________. - Inventory surplus - Error free work environment - Optimized production schedule - Clean and orderly work area

- Clean and orderly work area

The ability to __________ may be a person's most important factor to be successful. - Be technical - Read diagrams - Communicate - Be tolerant

- Communicate

What is the purpose of a kanban system? - Communicate needs within production - JIT method of moving products - Inventory counting system - Ordering system within shipping

- Communicate needs within production

Spoken, written, and electronic are three types of __________. - Email messages - Communication mediums - Programming - Kanban orders

- Communication mediums

What is the definition of manufacturing resource planning? - System to manage people within production - Computer system used to schedule production - Computer systems used to schedule people for production - Computer systems used to inventory material and completed products

- Computer system used to schedule production

Brainstorming, organizing, and editing are each a part of the full planning process for __________ a clear message. - Reading - Receiving - Disabling - Constructing

- Constructing

Production capacity is a measure of a department's ability to meet __________. - Customer complaints - Quality standards - Supplier demand - Customer demand

- Customer demand

The box selected for your product must have a bursting strength of at least 180 lbs per square inch. Which box certificate indicates a box with sufficient strength? - A - B - C - D

- D

New product design teams should perform a(n) __________ as early in the design process as possible. - Time study - Histogram analysis - Design failure modes and effects analysis - OSHA inspection

- Design failure modes and effects analysis

Jidoka builds quality into the manufacturing process. What four steps are used in jidoka? - Produce, inspect, produce, inspect - Discover, inspect, produce, inventory - Discover, produce, inventory, market - Discover, stop, fix, investigate cause

- Discover, stop, fix, investigate cause

When issued the incorrect, non-conforming, or wrong amount of parts from supply, use a __________ form to correct the issue. - Kanban stop - Production stop - Material requisition - Discrepant material

- Discrepant material

The floor manager/supervisor is typically familiar with __________. - Engineering procedures - Documentation regarding customer requirements - Marketing plans for increased sales - Future products

- Documentation regarding customer requirements

Customer relationship data is stored in a __________ that can be used to record concerns with specific products. - Notebook - Thumbdrive - ERP or database system - Employee handbook

- ERP or database system

What is the unit of measure for Part # FRM-102 described in the following manufacturing work order? - Feet - Each - Inches - Lot

- Each

Non-value-added activities are considered waste if they fall into one of the eight categories. Which waste includes poor workplace organization and layout issues? - Excess motion - Transportation - Excess inventory - Over-processing

- Excess motion

It is most important to clearly label any containers of __________ material before shipping. - Sponges - Scrap steel - Plastic pellets - Flammable or hazardous

- Flammable or hazardous

Forklift operators contribute to maintaining product quality by __________. - Following safety guidelines - Following correct storage procedures - Increasing stocking speed - Removing unused pallets from the warehouse

- Following correct storage procedures

Product damage can be avoided by __________. - Always lifting with your legs - Following packaging specifications - Using a forklift to lift oddly shaped objects - Stacking finished inventory as high as possible on a pallet

- Following packaging specifications

Lean culture must be deep within the company. What must the company be willing to do? - Give employees time to observe and study their workspace. - Give employees breaks to increase creativity. - Increase wait time between processes - Increase production time.

- Give employees time to observe and study their workspace.

Making sure that all necessary resources are available at the workstation when required __________. - Helps to optimize production and make workflow efficient - Creates a hostile work environment - Makes the workstation more ergonomic - Causes undue stress on the employee

- Helps to optimize production and make workflow efficient

If capacity is reached, reallocation of equipment and resources is one way to __________ to meet demand. - Address underperforming employees - Improve quality through increased inspections -Lower production costs - Increase production

- Increase production

Scheduling overtime is one of the ways to __________ when the production line is already operating at maximum speed. - Reduce defects - Improve operator morale - Increase quality - Increase production

- Increase production

If the correct raw material is not available, the employee should __________. - Use a similar raw material - Inform the supervisor - Call customer service - Complain to coworkers

- Inform the supervisor

Before packaging an item for shipment, the shipping agent should always check for a __________ indicating that the item meets compliance, approved, and is OK to ship. - Status card - Inspection label - Bill of lading - Statement of approval

- Inspection label

Bursting test strength on a box certificate tells the box's ability to withstand __________ of the amount shown. - Internal and external forces - Water damage pressure - Being dropped - Product weight

- Internal and external forces

A person working downstream on an assembly line is considered a(n) __________. - External customer - Internal customer - Supplier - Contractor

- Internal customer

Items should be placed in a box that __________. - Is larger than required so that the box can be used for multiple products - Has a removable lid - Is sized to fit so that it does not move excessively after cushioning material is added - Is attractive to customers

- Is sized to fit so that it does not move excessively after cushioning material is added

What is another name for lean production? - Light production - Just-in-Time - Minimal staffed production - Light process

- Just-in-Time

Shipping weight on a bill of lading is usually expressed in __________. - Grams - Ounces - Lbs or kgs - Feet or inches

- Lbs or kgs

__________ is responsible to align the team, establish direction, and to motivate and inspire. - The quality worker - Leadership - The vendor - A maintenance worker

- Leadership

A bill of lading can also be used to determine if emergency action is needed in case of a(n) __________ during shipping. - Flat tire - Bad weather is experienced - Leak or spill from a container - Road being closed

- Leak or spill from a container

What type of shipping uses a truck that may have to make two or more stops to different companies to achieve a full load? - Part-time (PT) - Full-truckload (FTL) - Less-than-truckload (LTL) - Hot-truckers (HT)

- Less-than-truckload (LTL)

A __________ provides information to the manufacturing department about the product that is to be made and authorizes inventory to be issued to begin the job. - Process routing sheet - Process plan - Manufacturing work order - Bill of materials

- Manufacturing work order

To help track spending and budgeting operating expenses, a __________ form is used to replenish supplies or tools needed for the job. - Costing - Tool manifest - Material requisition - Routing

- Material requisition

A barrier that interferes with good communication is called __________. - A message - Noise - Feedback - The medium

- Noise

An employee should locate and assist the appropriate contact if he/she __________. - Feels a competitor has a better process to complete the task - Needs an extra break - Notices a problem that would prevent customer specifications from being met - Knows they are working on a "hot job"

- Notices a problem that would prevent customer specifications from being met

Cycle counts involve verifying inventory on hand __________. - Once per year - On a continuous basis throughout the year - Monthly - As it leaves stock

- On a continuous basis throughout the year

Process cycle time is the time required to complete the production of __________ from start to finish. - Bottlenecks - A bad part - One unit of product - A machine run

- One unit of product

What are included on a manufacturing work order? - Customer address for shipping - Order and item number - Takt time and lead time - Throughput and kanban signal

- Order and item number

__________ does NOT help meet the process requirements and product specifications of a manufacturing order. - Manufacturing the product to meet product specifications - Overproduction - Looking for production related problems - Asking questions when something is unclear

- Overproduction

Item counts are verified by what? - Management - Physical inventory - Sales figures - Vendors

- Physical inventory

When facing multiple problems at once, the first step to take is what?- Prioritize them by greatest impact first - Implement corrective actions - Blame those responsible - Identify the cause

- Prioritize them by greatest impact first

Companies use __________ to determine how manufacturing methods are most likely to fail. - Process failure modes and effects analysis - Statistical Process Control - Pareto chart - Prototype design analysis

- Process failure modes and effects analysis

Customer lead time is the time between customer order and __________. - The first manufacturing process - Product delivery - Confirmation of order size - Inspection to ship

- Product delivery

What is the greatest amount of products a system can produce per day? - Throughput - Production capacity - Production Time - Takt time

- Production capacity

__________ should be consistent with a company's strategic goals and objectives and support the overall business plan. - Inspection reports - Defect reports - Manufacturing specifications - Production plans

- Production plans

When performing a finished goods inventory, you are counting what? - Product in the last stage of manufacturing - NCM products that have been painted - Products completed with manufacturing and ready to ship - Products sold and shipped

- Products completed with manufacturing and ready to ship

What is throughput? - Process to get materials through the production - Shipping time throughout the country - Products produced in a given amount of time - Products produced within one cycle of production

- Products produced in a given amount of time

Which of the following is a key action step of Standardize? - Free up space - Arrange items in the order of their use - Promote best practices - Reduce clutter in the work area

- Promote best practices

Companies should provide an environment that encourages team members to __________. - Criticize other team members at any time - Provide input during the entire problem-solving process - Attend meetings whenever they want - Report team meetings to the boss

- Provide input during the entire problem-solving process

Increased consistency of work-flow and quality can be achieved by __________. - Providing employees appropriate cross-training - Reducing cost of employee benefits - Increasing production downtime - Maximizing employee turnover rates

- Providing employees appropriate cross-training

JIT reduces excess inventory, waiting, and transportation by changing the traditional system of inventory to one that focuses on what method of moving inventory? - Pulling inventory meaning it moves when needed - Pushing inventory to waiting areas - Moving inventory into warehouses - Pulling inventory to reduce back injuries

- Pulling inventory meaning it moves when needed

__________ are used to communicate customer issues. - Audits - Customer communication reports - ISO 9000 reports - Quality reject reports

- Quality reject reports

When discussing SPC, the term that means the difference between maximum and minimum values in a data set is __________. - Range - Span - Headroom - Spectrum

- Range

In communication, to avoid making assumptions is a special responsibility of the __________. - Barrier - Receiver - Sender - Medium

- Receiver

Lean manufacturing is a method of eliminating waste. What is the purpose of eliminating waste? - Reducing landfill shipments - Reduce production cost - Reduce lead time - Reduce both cost and lead time while increasing quality

- Reduce both cost and lead time while increasing quality

One of the results of Sort is to do what? - Make sure everything has an assigned storage area - Store the most often used items closest to their point of use - Reduce the time to locate tools - Establish daily cleaning routines

- Reduce the time to locate tools

How does the 5S method aid in the goal of lean manufacturing? - Reduces the amount of inventory needed to operate the business - Produces the right amount of the right parts at the right time - Reduces the waste of excess motion, helps improve morale, and enables other lean methods to be more successful - Discovers what is wrong with the process, stops the process, fixes the immediate problem, and corrects the root cause

- Reduces the waste of excess motion, helps improve morale, and enables other lean methods to be more successful

Effective communication requires everyone to accept __________ in the process. - Criticism - Instructions - Fault - Responsibility

- Responsibility

To address customer quality issues, companies often use problem solving tools like fishbone diagrams, brainstorming, and __________. - Root cause analysis - Corrective action reports - Power point - ISO 9000 reports

- Root cause analysis

All shipping documents should be filed away in a __________ and in accordance to __________ policy, after shipment is complete. - Filing cabinet / employment - Box / customer - Desk drawer / auditor - Safe storage place / company

- Safe storage place / company

A __________ initiates communication by forming an idea to be shared. - Barrier - Receiver - Sender - Medium

- Sender

Communication is a process by which we assign and convey meaning in an attempt to create __________. - Shared understanding - Questions - The method of transmission - Culture barriers

- Shared understanding

In which 5S step does the employee look for damaged equipment, worn components, and misplaced objects? - Sort - Straighten - Shine - Standardize

- Shine

The purpose of the __________ is to identify materials loaded onto a truck, the hazards associated with that material, and any special handling instructions to be followed. - Bill of sale - Packing slip - Pallet manifest - Shipping manifest

- Shipping manifest

A production line can run no faster than its __________ step. - Fastest - Slowest - Smallest - Shortest

- Slowest

Judging tagged items is part of what 5S step? - Sort - Straighten - Shine - Standardize

- Sort

Perishable goods must be properly handled to prevent __________. - Someone from stealing them - Tripping hazards - OSHA fines - Spoilage

- Spoilage

The best medium to communicate and resolve a conflict would be __________. - Written - Electronic - Spoken - Blog

- Spoken

The stable operations within products allow the company to add this to its lean manufacturing core? - JIT - Standardization - Jidoka - Structure

- Standardization

Which 5S step involves formatting 5S work instructions so that they look and read alike? - Sort - Straighten - Sustain - Standardize

- Standardize

To maintain a consistently high-quality product, production processes must be __________. - Quick and rarely monitored - Developed as cheap as possible - Standardized and controlled - Minimal with many operator interactions

- Standardized and controlled

Measuring products and tracking process data is one way to apply __________ to improve quality. - Statistical Process Control - JIT - Predictive maintenance - Team members

- Statistical Process Control

Quality Assurance (QA) activities include using __________ and quality audits to measure effectiveness. - Kanban - Statistical process controls (SPC) - Computer aided drafting (CAD) - Staff meetings

- Statistical process controls (SPC)

In preparation for repeat orders from a customer, companies __________. - Store order information and product specifications on file - Design every product configuration available - Keep equipment ready to make the product - Always keep raw stock on hand

- Store order information and product specifications on file

Which 5S step uses labels to clearly identify equipment? - Sort - Straighten - Sustain - Standardize

- Straighten

What is often considered the most difficult step of the 5S process? - Sort - Straighten - Sustain - Standardize

- Sustain

What is the rate at which each product must be produced to keep up with demand? - Throughput - Lead Time - Takt time - Lean time

- Takt time

Top level management must commit to __________ to help sustain 5S success. - Pay raises - Promotions - Team building - A full staff

- Team building

One way to balance the line is to adjust each machine so __________. - Defects are the same - Material builds up at one station - The cycle times are the same - Takt time is faster

- The cycle times are the same

Prompt communication with a supervisor is necessary when __________. - The employee notices that he/she is ahead of schedule - An employee has overlooked a new break policy - There is a slight delay, even though it will not affect the production schedule - The production schedule cannot be met

- The production schedule cannot be met

The daily production schedule is used to allocate the necessary people and equipment to ensure that __________. - The required production goals are achieved - No one is just standing around - Equipment expenditures are justified - The employees understand that he/she is the boss

- The required production goals are achieved

The selection of a production area layout depends on __________. - The number of operators available - Timeline and budget - Space limitations - The type and volume of products produced

- The type and volume of products produced

The supervisor should be notified immediately if __________. - Purchasing is using a new vendor to supply the same material - Work is on schedule - The work order is incorrect - An order is complete

- The work order is incorrect

To identify and eliminate bottlenecks, the __________ required to complete each process must be determined first. - Extra workers - Cost - Time - Housekeeping

- Time

Creating backorders allows a company to save money by __________. - Waiting until a large order comes in allowing the setup cost to be shared across a large number of items - Moving these orders to the front of the production schedule - Substituting similar products - Collecting the money without shipping a product

- Waiting until a large order comes in allowing the setup cost to be shared across a large number of items

Root cause analysis is a common tool used to determine what? - The employee responsible for making a bad part - Which job a worker is best suited for - Why bad parts are being produced - The control limits on a control chart

- Why bad parts are being produced

A cellular manufacturing layout is used when making a __________ of similar products. - Small batch - Mass batch - Wide variety - Small variety

- Wide variety

__________ counts any materials that have been issued to a manufacturing order that have not been produced into a finished product. - Incoming goods inventory - Finished goods inventory - Production floor inventory - Work-in-progress inventory

- Work-in-progress inventory

The best medium to communicate complicated do-it-yourself instructions would be __________. - Written - Electronic - Spoken - Blog

- Written

Continuous improvement is based on what major goal? - Daily improvement - Zero waste - Structural changes - Increase improvements

- Zero waste