Exam #2 Chapters 5-8

Why is the added value of a flow unit not exactly the same as its labor content?

All processing times do not add value.

What is the best definition of kaizen?

Continuous improvement

Assuming a given product mix, what is the result when demand rates are divided by the highest implied utilization?

Flow rates.

___variables measure the quality of the outcome of a process.

Outcome

How should items be transported in order to implement single unit flow?

Piece-by-piece

Which probability do you multiply by 1,000,000 to get ppm?

Probability of a defective unit

Which principle of operational excellence refers to continuous process flows that match supply with demand?

Processes

What term is used to describe a repeated sequence of production activities?

Production cycle

What aspect of the Toyota Production System inspired James Womack to coin the term "lean"?

Production success

In which type of system does production occurs only because there is demand?

Pull

The goal of SMED is a setup process whose time can be described with how many digits?

Single

Statistical process control is based on what?

Statistical analysis

What is the best definition of implied utilization?

The difference between what is demanded (demand) from a resource and what it can provide (capacity)

Which factors might prevent a company from expanding capacity in all resources with an implied utilization of over 100%?

The margin of profit Costs of expansion

What can be inferred from a doctor's statement that "some patients have simple issues whereas other have more complex problems."

The process has multiple flows The process has flow-dependent processing times.

Identify a correct statement in the context of finding a bottleneck and flow rates in a process with flow-dependent processing times.

The resource with the highest implied utilization is the bottleneck.

In a kanban system, what triggers a production order?

The return of an empty container

What is true about environmental variables.

They are not under the control of management.

Which of the following is true of a robust process?

Variation in input variables does not lead to large amount of variation in outcome variables.

Which should be used to measure the capability of a process?

Variation in outcome variables

When is a sample is in line with past process outcomes?

When it falls within the lower and upper control limits.

The basic philosophy of TPS is that the production process should ___ production when a quality problem is discovered.

halt

Which metric allows you to deduce how much demand exceeds the capacity of the process?

implied utilization

The term kaizen means "process ___ ".

improvement

As the processing time increases at a step with a setup the utilization ___.

increases

At a resource with a setup, increasing the batch size ___ the capacity of the resource.

increases

Decreasing the processing time at a step that has a setup, but is not the bottleneck, and holding everything else constant, ___ the average inventory.

increases

If the flow rate of good output of a process increases--and everything else remains the same--then the process yield ___.

increases

Increasing the batch size at a step that has a setup, but is not the bottleneck, and holding everything else constant, ___ the average inventory level.

increases

Production ___ is used to smooth out variability in demand. (Enter only one word per blank.)

leveling

If the process yield decreases then that process needs to produce ___ units to get the same number of good units.

more

Rework means that a resource needs to process ___ (more/less) flow units

more

The longer the information turnaround time the ___ time an upstream resource will spend producing defective units.

more

The more steps in a process the ___ likely a defect.

more

Defects are detected based on variation in ___variables.

outcome

In a fishbone diagram, a horizontal arrow points at the name of the ___ variable to analyze.

outcome

The Japanese term for fool-proofing an activity is ___-___.

poka, yoke

We refer to a combination of different flow unit types moving through a process as a

product mix

At a step with a setup, inventory accumulates when that step is in ___.

production

A small batch size at a step with a setup will lead to a ___ amount of inventory.

small

A six-sigma process has 6 standard deviations on either side of the mean before reaching the ___ limit.

specification

Which production schedule for products of type A and B is a result of production leveling?

ABABABABABABABAB

What is the major advantage of the kanban system?

It limits inventory to just what is needed.

How does setup time affect production capacity?

Lowers it

Which actions are part of capability analysis?

Measure outcome variation. Compare outcome variation to outcome specifications. Determine likelihood of defects.

Which is an appropriate unit for measuring the demand rate when analyzing a process with flow unit dependent processing times?

Minutes

Consider the applications for a driver's license in the department of motor vehicles. Suppose those who are getting a driver's license for the first time must take an extra test that is administered by a designated staff member. What term describes the different roles in the driver's license process of those who have to renew their driver's license and those who are getting a driver's license for the first time?

Multiple flow units

What is generally represented by the use of multiple arrows in a process flow chart?

Multiple flow units

What information is provided by calculating target manpower?

Number of workers required

The estimate of the standard deviation of the output unit is based on ___ the output units.

a sample of

The distance between the center line and the LCL is ___ the distance between the center line and the UCL.

equal to

The higher the demand rate, the ___ the number of Kanban cards.

greater

With multiple flow unit types the bottleneck is the resource with the ___implied utilization.

highest

Autonomation refers to automation with a ___ touch.

human

The time when a process is doing nothing is known as ___ time.

idle

If a process improvement effort decreases the amount of time spent on non-value-added activities, then the value-added percentage will ___.

increase

Setup activities that can only be done when the machine is not producing are called ___ tasks.

internal

Another way to reduce setup time is to convert an ___ task into an ___ task.

internal, external

A rapid flow with little or no ______ is one of the pillars of TPS.

inventory

Two forms of waste are waste of a flow unit's time and waste of a ___ time.

resource's

Capacity invested in ___ at the bottleneck is lost from the perspective of the overall process.

rework

The extra or repeated activities performed on a defective flow unit are collectively called ___.

rework

A ___ process is designed to do well, even under very exceptional conditions.

robust

A ___ process is one where variation in input or environmental variables does not lead to large variation in outcome variables.

robust

The goal of single-minute exchange of die (SMED) is to reduce the ___ time.

setup

A mixed-model assembly strategy states that different products should be produced in ___ batches one after the other.

small

The greater the variation in outcome variables the ___ the process capability index.

smaller

The higher the process capability index, the ___ the ppm.

smaller

The larger the process capability index, the ___the target variation.

smaller

Assignable cause variation occurs because of a ___ change in input or environmental variables

specific

A beverage bottling company that states that all bottles filled beyond 20.01 ounces are too full. 20.01 ounces is an example of an upper ___ limit.

specification

For a p-chart the lower control limit is ___ standard deviations below the center line.

three or 3

Control charts plot data over ___.

time

The x-axis of a control chart depicts the ___ periods at which samples from the process are taken. (Enter only one word per blank.)

time

Implied Utilization =

total demand at the resource / capacity at the resource

A one unit flow often requires a facility layout to reduce the need for ___ batching.

transport

Mura refers to a(n) ___ workflow.

uneven

Which metric cannot exceed 100%?

utilization

Ideally, the time a flow unit spends in processing is ___ time.

value-added

When dealing with flow-dependent processing times, the processing times for each flow unit ___.

vary depending upon the particular patient type

An operation is lean if it simultaneously strives for a reduction of ___ in its capacity and in the time a flow unit spends in the system.

waste

In the house representation of TPS the roof represents the principle of ___ reduction.

waste

The time a flow unit spends in inventory is ___ time.

wasted

A unit is acceptable if it falls ___ the specification limits.

within

To ensure a small number of defects, the control limits should fall ___ the specification limits.

within

Ideas for fool-proofing an activity in order to prevent a previously detected defect from recurring often involve a new ___ standard.

work

The eighth source of waste is the waste of ___ intellect.

worker

Suppose a faucet adds water at a rate of 1 gallon per minute. For which drain flushing rate will inventory accumulate the fastest?

.6 gallon per minute

If one resource in a process ALWAYS produces defective parts, then the process yield of that resource is ___ %.

0

Consider a two-step process where the first step produces at a rate of 2 units per minute for the first 30 minutes of an hour and then goes into setup for the second 30 minutes of an hour. The second step produces at a rate of 1 unit per minute for the entire hour. Assuming the beginning inventory in a buffer before step 2 is zero, after one hour the inventory in that buffer will be ___.

0 units

How many different types of flows are entered into each column in the demand matrix?

1

Rank--from first to last--the following steps for finding the bottleneck and capacity in a process with rework.

1. at each resource with rework, evaluate the weighted average processing time. 2. evaluate the capacity of each resource. 3. evalute -- for each resource -- the implied utilization.

List in order the steps required to find the bottleneck and flow rates in a process with multiple flows, beginning with the first step.

1. compute the demand matrix 2. determine the total demand rate for each resource. 3. determine the capacity for each resource. 4. calculate the implied utilization for each resource. 5. compute the flow rate for each flow unit.

Place the steps for finding bottlenecks and capacity in the proper order, with the first step at the top.

1. computer workload matrix. 2. add workloads for each resource. 3. compute available time at each resource. 4. compute implied utilization at each resource. 5. divide a unit of time by highest implied utilization.

Suppose demand is for 200 gallons of chicken noodle soup and 100 gallons of tomato soup. What fraction of a batch should be dedicated to chicken noodle soup?

2/3

The pareto principle states that ___ % of causes account for 80% of problems.

20 or twenty

Four workers will provide an hourly capacity of ___.

240 minutes

Consider a two-step process where the first step produces at a rate of 2 units per minute and the second step produces at a rate of 1 unit per minute. Assuming the beginning inventory in a buffer before step 2 is equal to zero, the inventory in that buffer after 30 minutes will be _blank​_.

30 units

How many presses would be required to produce 10,000 copies of a 300 page book with Gutenberg's printing press technology without performing any setups?

300

Imagine a process that produces four different products with a machine that requires a setup before each product change-over. What is the minimum number of machines required to remove the need for additional setups?

4

At a step with a setup, which will require larger batch sizes (and hence more inventory) to meet demand?

4 products with total demand equal to 200 gallons per hour

550 gallons of soup is produced in a production cycle, 360 out of every 480 gallons produced must be chicken noodle soup and 120 out of every 480 gallons must be tomato soup. Thus, of the 550 gallons, how many gallons should be chicken?

412.5

If the demand rate for a process is 80 units per hour and the rate of the bottleneck in a process is 90 units per hour then the target capacity is ___ units per hour.

80

If parts flow from machine A to machine B and then to machine C, then which pair of machines can be farther apart from each other?

A and C

Which are examples of assignable cause variation?

A new worker performs a task more slowly than an experienced worker. A bottling machine constantly overfills bottles by .2 ounces.

Which of the following statements are true about a process that involves rework?

A process involving rework can lengthen flow times. A process that includes rework has multiple flows. A process that involves rework has different processing times.

In a process flow diagram with multiple types of flow units, what is generally used to represent flow units?

Arrows

What was the basic flaw in Taylor's view of workers?

As animals who had to be trained

Which statements are true about the relationship between batch size and capacity?

As batch size gets larger, capacity increases at a lower rate. Increasing batch size increases capacity.

Abnormal outcome variation can be attributed to which type of variation in input or environmental variables?

Assignable cause

Which kind of variation is due to a systematic issue?

Assignable cause

What term is used to describe flow units that do not complete a process?

Attrition losses

Which term refers to combining machines with the intelligence of workers?

Autonomation

What term is used to describe the slowdown that results when batch size reduces capacity in a production step?

Bottleneck

What effect have large buffers of inventory been shown to have on workers?

Causes them to slow down

Drag the purpose of a limit to the limit it describes.

Control limits = indicates whether the process is behaving the same way it did in the past Specification limits = indicates whether the process meets the requirements of the customer.

Which factors suggest that kanban is the best inventory control system to use?

Cost and effort to store products are low Products required with short lead time

Which are elements of make-to-order systems?

Customers willing to wait Low volume, high variety High storage costs

What do the leaves of an event tree represent?

Defects Good outcomes

What actions were organizations following Taylor's principles of scientific management most likely to take?

Demand high productivity Hire industrial engineers Study worker movements

What is the first factor to be calculated when analyzing a process with multiple flow units?

Demand matrix

What information is required to compute takt time?

Demand rate Available time

___ lines that point to the main line in a fishbone diagram, can capture either input or environmental variables.

Diagonal

What is the best definition of product mix?

Different types of flow units going through a process

A root cause is a change in which kind of variable? (More than one may be correct.)

Environmental Input

Which statement is true about defect probability?

Even an extremely low probability of defects can cause big problems.

True or false: There is one processing time for a process that requires rework.

False Reason: There is also a processing time for rework which is different from the processing time for a normal flow unit.

True or false: If a resource has implied utilization greater than 100%, then it is always the bottleneck.

False Reason: There may be multiple resources with implied utilization greater than 100%.

___ proofing refers to designing a task so that a worker can not complete it in a way that would introduce a defect.

Foolproofing

Who is considered the father of scientific management?

Frederick Taylor

In the Toyota Production System, insights of which employees are leveraged to improve a process?

Front-line

Genchi genbutsu refers to which approach to gathering information?

Going and observing yourself

What is represented by the bars in a Pareto diagram?

How often a defect occurs

Which are examples of input variables in an agricultural process over which management has control?

How often plants are watered How close together seed is planted What type of fertilizer is used

Which are important steps in reducing setup time?

Identify internal and external activities Decrease the number of internal activities Change internal activities to external

What term is used to describe the time in which a process is neither setting up or producing?

Idle time

What are examples of waste of a resource's time?

Idle time on machines Duplication of worker efforts

Which are advantages of U-shaped organization of processing flow?

Increases employee flexibility Encourages multitasking Allows employees to assist each other

How does increase product variety affect setups?

Increases them

On which variables in a process does management exert the most control?

Input

For a farmer growing corn, what type of variable is the frequency with which the crops are watered using an irrigation system?

Input variable

What happens to capacity per unit of time as implied utilization increases?

It decreases.

When processing time increases, what happens to capacity?

It decreases.

What happens to inventory falls when a production step is in setup?

It falls.

What has historically happened to utilization during wartime?

It has risen to over 90%.

What happens to the workload of a resource if the processing time per flow unit increases and everything else remains the same?

It increases.

Which of the following is a pillar in the house representation of TPS?

Just-in-time production

The Japanese word ___ describes the process of analyzing the root cause of a quality problem on the shop floor.

Kaizen

___ is the process control system wherein an upstream resource replenishes what demand has withdrawn from the downstream.

Kanban

What term is used to describe a processing operation that eliminates as much waste as possible?

Lean

Which action is most likely to lead to improvement in a demand-constrained process?

Lowering costs

Suppose demand for a product is 100 units a day and a factory produces seven days a week. Which production schedule would be in line with the TPS philosophy toward pace?

Make 100 units every day

How is the available time at each resource computed?

Multiply number of workers by 60 minutes.

What formula is used to determine hourly capacity expressed in minutes of work per hour at a resource?

Multiply the number of workers by 60 minutes in an hour.

In a process with no defects, how can process yield be calculated?

Multiply the yields of each resource

___ is a Japanese word that refers to an overburdening of workers or equipment.

Muri

___is a Japanese word that refers to an overburdening of workers or equipment.

Muri

Which are terms used to describe variations that may appear in output, even when inputs are the same?

Natural variation Common cause variation

Drag the description of work to its appropriate category

Non-value-added work = necessary because of how current process operates Value-added work = necessary to transform flow unit from inputs to output the customer wants

Demand Matrix D(i, j) =

Number of flow units of type j that need to be processed at resource i

The process capability index is the ratio between the specification and the variation in which type of variable?

Outcome

Which variables are used to measure the quality of process output?

Outcome

Which variables measure the quality of the output of a process?

Outcome

When calculating the utilization of a step with a setup, what information is used in the denominator?

Output rate when producing

At what level of implied utilization can a case be made for increasing capacity in a resource, even if it is not yet a bottleneck?

Over 100%

What type of waste is involved when a process creates too many flow items too soon?

Overproduction

Which of the following are flow units in a hospital emergency room?

Patients who need to be treated immediately Patients who need xrays Patients who can wait for treatment

Which principle of operational excellence refers to respectful interactions with employees that emphasize skill development and growth?

People and partners

The Japanese word ___-___ describes the process of preventing the recurrence of a problem by implementing improvements.

Poka, yoke

In the context of baking cupcakes for sale later, which activities are setups?

Pre-heating the oven Cleaning the baking tins between batches The baking of the batch of cupcakes

Which factors indicate that a make-to-order system should be used?

Products are expensive Customers are willing to wait for their orders Products are hard to store

Upon discovering a defect, which of the following actions would represent the TPS philosophy of quality? (Check all that apply.)

Pull a cord that stops the production line immediately. Thoroughly analyze the root cause of the problem.

Which type of system allows inventory to keep accumulating?

Push

What kind of economy can cause utilization to rise to over 80%?

Quickly growing

What is the best definition of scrapping?

Removing defective flow units from a process

In a demand matrix, the columns correspond to various flow units. What information is entered in the rows?

Resources

Which source of waste is involved when workers must perform a particular operation on a flow unit multiple times because of quality issues?

Rework

What effect does rework have on demand rates for a resource?

Rework increases demand rates.

What is the effect of rework at a bottleneck step on process capacity?

Rework will decrease process capacity

___ stock is extra inventory kept in the system in case of defects or breakdowns.

Safety

A small batch size at a step with a setup leads to low capacity because the step spends much of its time in what mode?

Setup

How is the time to complete setup activities related to the number of units subsequently produced.

Setup time is not related to the number of units.

What is the advantage that typically offsets setup times?

Shorter processing times

Drag the source of each type of limit to the limit it relates to. Instructions

Specification limits = business tolerances for when a unit is a defect Control limits = measurements of past process outcomes

What factors are needed to compute target manpower?

Takt time Labor content

What is the target capacity in a supply-constrained process?

The capacity of the bottleneck

What are the best perspectives for making time visible?

The flow unit Inventory

What is the best definition of process yield?

The number of good units produced across all resources

Which is the best definition of yield?

The percentage of good units produced at a resource

Which is the most likely reason that capacity alone does not dictate the bottleneck?

The resource with the lowest capacity may be visited the least.

What is true about flow units when different products follow different paths through a process?

There are multiple flow units.

Which statements are true of p-charts?

They track the percentage of defective units over time. P represents the percentage of defective units. They are attribute-based.

Under the principles of genchi genbutsu and kaizen, who should collect data how work is performed in order to improve the process?

Those performing the work

What is the best definition of changeover time?

Time needed to switch between production types

True or false: To evaluate a process with rework, it is necessary to compute a weighted average processing time.

True Reason: Since the processing time for rework is different from the original processing time, one must compute a weighted average processing time. The capacity of the resource is one divided by the weighted average processing time.

Depending on where the loan application exits the process, we can distinguish between four types of loan applications:

Type 1: (funded loans) visits all resources in the process. Type 2: (withdrawn after closing) visits all resources in the process except for the manager. Type 3: (withdrawn after underwriting) only requires work at interviewing and at underwriting as the customer withdraws the loan application. Type 4: (rejected by underwriting) only requires work at interviewing and at underwriting as the loan application is rejected.

When is outcome variation is expected to be due to an assignable cause?

When the variation does not fit into the historical pattern of variation

What term is used to describe demand for work?

Workload

___ inventory helps detect-stop-alert as it makes quality problems more immediately apparent.

Zero

To calculate demand for a resource in minutes per hour with different flow unit types, you ___ the times spent serving each flow unit type.

add

To calculate the total demand for a resource, you ___ the workloads associated with each customer type.

add

X-bar charts can be used to document trends over time and to identify unexpected drifts (e.g., resulting from the wear of a tool) or jumps (e.g., resulting from a new person operating a process step), corresponding to ______ causes of variation.

assignable

Whether they are rejections or withdrawals, we refer to flow units that exit the process before completing it as

attrition losses

A ___ process is one where products are made in collections.

batch

As the flow rate at a step with a setup decreases, the utilization ___.

becomes lower

Rework has the most impact on process capacity when it occurs at the ___ step.

bottleneck

Information turnaround time depends on the size of the ___ between the upstream and downstream resource.

buffer

Low defect rates ___ result in unacceptable outcomes.

can

Process ___ is based on comparing the current amount of outcome variation against outcome specifications.

capability

The framework for statistical process control begins with ___ analysis.

capability

The "just right" batch size makes a smart trade-off between ___ and inventory.

capacity

To understand how much improvement potential there is one must first measure what percentage of a machine's or a worker's ___ is used productively.

capacity

When implied utilization is greater than 100%, the process is ___ constrained.

capacity

To calculate the ___ line of a control chart you compute the average of the mean for every period.

center, X-double bar, or X-bar-bar

The 60-minute setup time can also be called as a(n) ___ time.

changeover or switchover

Resources that are ___ to each other in the process flow diagram should also be co-located in physical space.

close

Genchi genbutsu emphasizes solving problems by ___.

collection and analysis of data by front-line workers

The second step in the framework for statistical process control is ___ analysis.

conformance

High inventory levels tend to _blank​_ quality problems.

cover up

Non-value-added work is those movements that must be done to complete a unit but do not add value in the eyes of the ____.

customer

A production ___ is a repeating sequence of produced units.

cycle

If the flow rate of the process as a whole increases, but the batch size and processing time at a step with a setup stays the same, then maximum inventory will ___.

decrease

As processing time increases, the output rate when producing ___.

decreases

As the flow rate of the overall process decreases utilization at a step with a setup ___.

decreases

Decreasing the processing time at a step that has a setup, but is not the bottleneck, and holding everything else constant, ___ the maximum inventory.

decreases

Increasing the yield ___ the number of flow units that need to be processed to get a certain number of good flow units.

decreases

A root cause is a change in an input or environmental variable that initiated a ___.

defect

The ___ probability is the likelihood a randomly chosen flow unit does not meet specifications.

defect

The process capability index tells us how many standard deviations we can move away from the statistical mean before causing a(n) ___.

defect

The target variation is the largest amount of variation that does not exceed a given ___ probability.

defect

Removing ___ flow units from the process is known as scrapping.

defective

Heijunka refers to producing as close as possible to the true rate of ___.

demand

In a table used to calculate implied utilization, each column is used to find the resources capacity and total ___.

demand

To implement single unit flow, you should level the ___ rate.

demand

How many flow units of each type are flowing through each resource is summarized by the

demand matrix

To calculate the workload of a resource that serves different flow unit types, one must know which of the following?

demand rate for each flow unit type processing time for each flow unit type

Which of the following are the goals that we want to accomplish when determining how much work each resource is capable of doing?

determine the maximum flow rate evaluate the actual flow rate through the process find the bottleneck

The main difference between a process flow diagram with one type of flow unit and a process flow diagram with multiple types of flow units is

different arrows to capture the different types of flow units

Capacity grows at a ___ rate as batch size increases.

diminishing

An airline tracking defects corresponding to lost luggage, a pharmacy trying to reduce the number of patients who were provided the wrong drugs, or a data entry operation struggling with handwriting recognition all face ___ outcomes (a unit is either defective or not).

discrete

Capacity in emergency room patients per time unit equals demand ___ implied utilization.

divided by

Environmental variables ___ (do/do not) affect process outcomes.

do

OEE stands for overall equipment ___.

effectiveness

Inventory is controlled in a Kanban system because production occurs at an upstream resource only when it has an ___ container.

empty

Defects are caused by variation in ______ variables.

environmental input

At a given resource, the ratio of total demand to capacity is ___ implied utilization.

equal to

A(n) ___ tree shows which combination of events leads to the outcome of a unit without defects.

event

Setup activities that can be done while the machine is producing are called ___ tasks.

external

Which of the following is the most important goal when using capacity addition to improve a process with multiple flows?

find the bottleneck

The TPS motto related to reducing rework is "Do it right the ___ time".

first

A benefit of the U-shaped line is that it allows for more worker ___.

flexibility

The target capacity for a resource is the smallest capacity that does not reduce the ___ of the process.

flow rate

Yield of resource =

flow rate of good output at the resource / flow rate of input = 1 MINUS flow rate of defects at the resource / flow rate of input

The higher the safety stock, the ___ the number of Kanban cards.

greater

In a demand-constrained process with multiple flows, the capacity for each flow is ___ its demand.

greater than

Inventory accumulates in a process when the inflow rate is ___ the outflow rate.

greater than

Inventory accumulates in a process when the inflow rate is ___the outflow rate.

greater than

To have an implied utilization that is greater than 100%, a resource must face demand that is ___60 minutes per hour.

greater than

As processing time increases the batch size that yields the target capacity ___.

increases

As target capacity increases the batch size that yields that target capacity ___.

increases

As the processing time at a step with a setup increases, the utilization ___.

increases

Increasing the batch size at a step that has a setup, but is not the bottleneck, and holding everything else constant, ___ the maximum inventory level.

increases

Little's Law enables one to calculate flow time, while flow rate is constant, indirectly by examining ___.

inventory

In a ___ system, production instructions are communicated to an upstream step when there is consumption at a downstream step. (Enter only one word per blank.)

kanban

A large batch size at a step with a setup will lead to a ___ amount of inventory.

large

The looser the design specifications (e.g. the larger the quantity USL-LSL) the ___ the target variation.

larger

A process wherein each step reliably performs high-quality work will have ___ attrition losses.

low

In a ___ system, each flow unit is explicitly tied to a specific customer order.

make-to-order

In a table used to calculate implied utilization, the resource's capacity and total demand are expressed in ___.

minutes of work

Variation that is due to randomness is referred to as ___ variation or ___ cause variation.

natural variation or common cause variation

In a table used to calculate implied utilization, each resource will occupy ___ row(s).

one

Make-to-___ is the process control system wherein work is released into the system only after a customer order has occurred.

order

Specifications are acceptable values for ___variables that indicate whether the output of a process is defective.

outcome

For a p-chart the center line is the average _______.

percentage of defects over all samples

High inventory and ___ quality go hand in hand.

poor

The P in SPC stands for ___

process

Resources with a setup generally have a shorter ____ time than the next best alternative.

processing

The output rate when producing equals one divided by the ___ time

processing

The combination of different flow unit types moving through a process is referred as ___ mix.

product

When all steps have to be performed correctly for a unit to be good the probability of a good unit is the ___ of the probability of each step being performed correctly.

product

In a ___ system, inventory is a managerial decision.

pull

In a ___ system, flow units are allowed to enter the process independent of the current amount of inventory in process and the demand rate.

push

Defect probability is the likelihood with which a ___ chosen flow unit does not meet specifications.

randomly

Which factor should govern the speed of a process?

rate of demand

When determining the bottleneck in the presence of multiple flow units you must recognize that not every flow unit is going to every ___.

resource

Idle time is a waste of a ____ time.

resource's

The objective of the OEE framework is to identify what percentage of a ___ time is value-added and what percentage is wasted.

resource's

The idea of the "5 Whys" is to keep asking "why did this happen" until a ___ cause is found.

root

The input or environmental variables for which the variation lead to a defect are referred to as the ___ cause of the defect.

root

The output of a process is determined to be defective by comparing outcome variables against a set of ___.

specifications

Capability analysis helps one infer that one process is better than another by measuring the process ___.

spread or variation

A six-sigma process has six ___ ___ on either side of the mean and the specification limit.

standard deviations

If the length of time required by an external setup increases then the batch size should ___.

stay the same

The height of an event tree corresponds to the number of ___.

steps in the process

The defect probability is the ___ of the probability that a unit falls below the LSL and the probability that a unit falls above the USL.

sum

The ___ variation is the largest amount of variation in a process that does not exceed a given defect probability.

target

If each resource in a process has a yield of 100%, then the process will have a yield of ___%.

100%

What term is used to describe a collection of units?

Batch

Which type of outcome is exemplified by an automobile manufacturer tracking the frequency with which cars are defective?

Binary

Which type of outcome is represented on a p-chart??

Binary

Which line on a control chart is an average across averages?

Center line

For a farmer growing corn, what kind of variable is the weather?

Environmental

If flow rate remains the same, and a resource produces more defects, what will happen to the yield of that resource?

It will be lower.

What effect is rework likely to have on a bottleneck?

It will make it worse.

What is true about flow units in a process where different products require different amounts of a resource's time?

There are multiple flow units.

A counter-measure to overproduction is Just in ___ production.

Time

Which are factors in figuring replenishment time?

Time to produce a container of units Setup time Transportation time

True or false: The basic idea of the "Five Whys" is to continually question whether a potential cause is the ROOT cause or merely a symptom of the root cause.

True

The more available time, the ___ the takt time.

higher

The higher the capability index, the ___ likely the process will produce a defect.

less

The capacity of a step with a setup is ___ its output rate when producing.

less than

To have an implied utilization less than 100%, a resource must face a demand rate that is ___ 60 minutes per hour.

less than

The probability of a unit falling below the LSL and the probability of a unit being above the USL is the same when the ___ of the distribution is in the middle of the tolerance interval.

mean

The larger the sample size, the ___ the estimated standard deviation.

smaller