OM Exam 2
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
e
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
e
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
e
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
a
Consider a workstation that can process 4 units per minute. It takes 2 hours to receive an order from the previous station. The container size is 10 units. The factory sets safety stock at 20 percent of demand during lead time. How many kanbans are needed for the workstation? a) 57.6 b) 48 c) 0.96 d) 9.6 e) 28.8
a
T/F: 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 kanban blitz.
False
T/F: If the goal is to reduce the amount of inventory in the system, the number of Kanban cards should be increased.
False
T/F: JIT facilities are lacking in floor space.
False
T/F: Often the best quality problem resolution solution involves a complex answer as the organization is a complex organization.
False
T/F: Services organizations cannot use the JIT philosophy to reduce cycle time.
False
T/F: Successfully implementing JIT requires that it be done as quickly as possible.
False
T/F: With a kaizen system there is no excess production because the only products and quantities produced are those specified by the kaizen.
False
True/False: According to JIT, by eliminating inventory we can clearly identify obsolete products and work on eliminating them.
False
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
a
T/F: A key outcome of JIT is that organizational barriers are eliminated.
True
T/F: Being able to keep costs low while changing the volume of production is an example of flexibility.
True
T/F: Bottom-round management includes consensus management by committees or teams.
True
T/F: By focusing on value-added processes, JIT is able to achieve high-volume production of high-quality, low-cost products.
True
T/F: Continuous improvement is called kaizen by the Japanese.
True
T/F: External setups can be done while the machine is running.
True
T/F: JIT concepts that are applicable to service organizations include use of multifunction workers.
True
T/F: JIT considers people to be a company's most precious resource.
True
T/F: JIT considers waste anything that does not add value.
True
T/F: Just-In-Time relies on cross-functional worker skills.
True
T/F: Just-in-time organizations rely on employees to work together.
True
T/F: The broad view of JIT is now often termed lean production or lean systems.
True
T/F: The challenge for service organizations is synchronizing their production with demand.
True
T/F: The manufacturing process in JIT starts with the final assembly schedule.
True
T/F: There are two types of Kanban cards, production Kanban and withdrawal Kanban.
True
T/F: With regard to suppliers, JIT typically requires information sharing.
True
True/False: JIT manufacturing cannot succeed if set-up costs are too high.
True
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
a
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
a
JIT believes in developing __________ relationships with suppliers. a) Long-term b) Adversarial c) Arms-length d) Temporary e) Distant
a
JIT is a __________ system. a) Pull b) Push c) Lead time d) Preventive maintenance e) Closed
a
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
a
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
a
Regular inspections and maintenance designed to keep a machine operational is __________ maintenance. a) Preventive b) Breakdown c) Unscheduled d) Emergency e) Unnecessary
a
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
a
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
a
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
a
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
a
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
a
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
c
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
b
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
b
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
b
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
b
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
b
Kaizen is a Japanese term referring to __________________________. a) just-in-time production b) continuous improvement c) employee involvement d) concurrent engineering e) simplicity
b
Poka-yoke means a) Using color coding b) Foolproofing c) Using process control charts d) Preventive maintenance e) Undercapacity scheduling
b
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
b
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
b
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
b
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
b
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
b
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
b
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
b
Unlike JIT traditional quality control systems use a) quality circles b) quality plans c) control charts d) acceptable quality levels e) quality applications
d
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
c
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
c
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
c
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
c
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
c
JIT manufacturing cannot succeed if __________costs are too high. a) Variable b) Fixed c) Set-up d) Depreciation e) Marginal
c
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
c
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
c
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
c
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
c
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
c
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
c
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
c
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
c
With JIT there are two types of Kanban cards, production Kanban and __________ Kanban. a) Buffer b) Transaction c) Withdrawal d) Logistics e) Sales
c
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
d
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
d
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
d
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
d
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
d
JIT considers __________ to be a company's most precious resource. a) Capital b) Productive equipment c) Information d) People e) Vision
d
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
d
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
d
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
d
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
d
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
d
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
d
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
d
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
d
__________ 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
d
Consider a workstation that can process 4000 units per hour. It takes 15 minutes to receive an order from the previous station. The container size is 20 units. The factory sets safety stock at 20 percent of demand during lead time. How many kanbans are needed for the workstation? a) 16 b) 3600 c) 50 d) 10 e) 60
e
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
e
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
e
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
e
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
e
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
e
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
e
Small lot production a) Increases inventory b) Decreases flexibility c) Reduces setup d) Increases excess processing e) Shortens lead time
e
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
e
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
e
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
e