OPS Management - Chapter 7, Quiz 3 operations, chapter 5 short, 315 CH. 3 and 9 Quizzes, Operations Management Test 2, 315 CH. 3 and 9 Quizzes, mgnt 2, chapter 5 for exam 3, Operations Management Ch 5, Operations Management 7

t

A bottleneck process has the lowest capacity and the longest total time from the start to the finish.

bottleneck

A(n) ________ is an operation that has the lowest effective capacity of any operation in the process, and thus limits the system's output.

The focus for a process improvement exercise should be on balancing:

A) Flow

Balance delay could be described as the:

A) amount by which efficiency falls short of 100 percent.

The second step in Theory of Constraints application, "exploit the bottleneck(s)," means that the analyst should:

A) create a schedule that maximizes the throughput of the bottlenecks.

Consider consecutive processes A-B-C, where process A has a capacity of 20 units per hour, process B has a capacity of 25 units per hour, and process C has a capacity of 30 units per hour. Where would an operations manager want any inventory?

A) in front of process A

A line that produces several items belonging to the same family is called a:

A) mixed-model line.

inventory

According to the Theory of Constraints, all the money invested in a system in purchasing things that it intends to sell is

Question 27 Bottlenecks exist in which type of manufacturing​ processes? batch process job process line process All of the above.

All of the above.

constraint

Any factor that limits the performance of a system and restricts its output is a(n)

Question 29 Which of the following is characteristic of a kanban​ system? At least one card is associated with a container of process input material. It has no control over the movement of containers from​ source/storage to the production process. It serves as a push mechanism. Each container contains a different number of​ non-defective parts.

At least one card is associated with a container of process input material.

What is the definition of "theoretical maximum efficiency"?

B) It is the efficiency that could be obtained by a solution that achieves the theoretical minimum number of stations

A line balance that is 100% efficient must:

B) be using the theoretical minimum number of work stations

The fifth step in Theory of Constraints application, "do not let inertia set in," means that the analyst should:

B) repeat the analysis to identify and manage new set of constraints.

The third step in Theory of Constraints application, "subordinate all other decisions to Step 2," means that the analyst should:

B) schedule non-bottleneck processes to support the bottleneck schedule.

There are three consecutive steps in a customer service process. The first two steps are each capable of serving 25 customers per hour while the third step can process only 20 customers per hour. Which of the following statements regarding this system is true?

C) If the first two steps are run at full capacity, then the third step has a waiting line.

Practical application of the Theory of Constraints involves the implementation of all of the following steps EXCEPT:

C) Reduce the capacity at the bottleneck(s).

The fourth step in Theory of Constraints application, "elevate the bottleneck(s)," means that the analyst should:

C) consider increasing capacity of the bottleneck.

Use the process flow diagram to determine which of these events has the greatest net benefit.

C) increasing the capacity at Station C to 7 units per hour

Instead of dividing by nc to determine the efficiency of a line balance, you could divide by:

C) the sum of the task times plus the sum of the idle times

In a drum-buffer-rope system, the lot size that moves from one work center to another for additional processing is a(n):

C) transfer batch.

a

Consider consecutive processes A-B-C, where process A has a capacity of 20 units per hour, process B has a capacity of 25 units per hour, and process C has a capacity of 30 units per hour. Where would an operations manager want any inventory? A) in front of process A B) in front of process B C) in front of process C D) Inventory should not exist anywhere.

Which of the following statements regarding setups is TRUE?

D) A TOC analyst would not be concerned with setup times on non-bottleneck machines

According to the Theory of Constraints, the four operational measures of capacity include all of the following EXCEPT:

D) Delivery lead times

Which one of the following statements about line balancing is best?

D) If a line's balance delay is minimized, its efficiency is maximized

The most controversial aspect of line-flow layout is:

D) behavioral response.

Use the process flow diagram to determine which of these events has the greatest net benefit.

D) reducing the flow time at Station D from 12 to 10 minutes

Work should be released into the system when:

D) the bottlenecks need work.

Question 8 What are the required predecessors of activity​ H? Image 2.PNG A through​ F, including E Activity H has no required predecessors. D E​ & G

E​ & G

A competent operations manager should first eliminate all of the bottlenecks from the process.

False

According to the Theory of Constraints, the four operational measures include inventory, throughput, delivery lead times and utilization.

False

Any system composed of resources that are operating at maximum output will, by definition, have maximum output for the entire system.

False

Immediate predecessors are the smallest units of work that can be performed independently.

False

In a shop managed according to TOC principles, inventory is needed only in front of bottlenecks in order to prevent them from sitting idle.

False

Lanny discovers that the bottleneck is the riveting machine so he schedules all production around when that machine is available. This is an example of elevating the constraint in the five-step constraint management process.

False

Line balancing strives to create workstations so that the capacity utilization for the bottleneck is much higher than for the other workstations in the line.

False

Paced lines require that inventory storage areas be placed between stations.

False

The process with the least capacity is called a bottleneck if its output is still greater than the market demand

False

Question 7 Which one of the following statements about line balancing is​ best? The theoretical minimum number of stations can never be​ achieved, hence the name​ "theoretical." If the desired output rate​ increases, the cycle time also tends to increase. If a​ line's balance delay is​ minimized, its efficiency is maximized. If a precedence relationship exists between A and​ B, they cannot be assigned to the same station.

If a​ line's balance delay is​ minimized, its efficiency is maximized.

c

In a drum-buffer-rope system, the lot size that moves from one work center to another for additional processing is a(n): A) process batch. B) operations batch. C) transfer batch. D) rope batch.

profit, bottleneck

Instead of producing products with the highest profit margins, operations managers should focus on the ________ generated at the ________.

Question 18 Which of the following statements is TRUE with regard to the eight types of waste that must be eliminated to implement lean​ systems? Product damage and deterioration result from using expensive high precision equipment. Workminus−inminus−process inventory is the direct result of underutilization of employees. Manufacturing an item before it is needed helps an organization detect and reduce defects. Jobs with excessive motion should be redesigned.

Jobs with excessive motion should be redesigned.

Question 11 Which of the following is NOT a benefit of small lot size for lean​ systems? Potential increase in process setups Enables a uniform system workload ​Reduction-of-cycle inventory Reduction in product lead times

Potential increase in process setups

Question 9 Which of the following best characterizes JIT​ systems? Annual review of operation methods Pull method of materials flow Build inventory at a modest rate Push method of material flow

Pull method of materials flow

28-30

Refer to worksheet

Question 15 Which of these terms is one of the Five​ Ss? Substitute Shine Supply Store

SHine

101-116

Study on Worksheet

Question 26 The theory of constraints principles outlined are NOT applicable to what type of​ processes? TOC is applicable to all of the above processes. large hospital processes large manufacturing processes large service processes

TOC is applicable to all of the above processes.

Which one of the following statements is best concerning line balancing?

The "largest number of followers" rule assigns as quickly as possible those work elements most difficult to fit into a station.

b

The fifth step in Theory of Constraints application, "do not let inertia set in," means that the analyst should: A) create a schedule that maximizes the throughput of the bottlenecks. B) repeat the analysis to identify and manage new set of constraints. C) consider increasing capacity of the bottleneck. D) schedule non-bottleneck resources to support the bottleneck.

a

The focus for a process improvement exercise should be on balancing: A) flow. B) capacity. C) workload. D) time.

c

The fourth step in Theory of Constraints application, "elevate the bottleneck(s)," means that the analyst should: A) create a schedule that maximizes the throughput of the bottlenecks. B) repeat the analysis process to look for other bottlenecks. C) consider increasing capacity of the bottleneck. D) schedule non-bottleneck resources to support the bottleneck.

d

The process batch at the constraint in a drum-buffer-rope system should be: A) the same size as that at any non-constraint. B) the same size as the transfer batch. C) of such a size as to maximize the number of setups for the constraint. D) of such a size as to improve utilization of the constraint.

a

The second step in Theory of Constraints application, "exploit the bottleneck(s)," means that the analyst should: A) create a schedule that maximizes the throughput of the bottlenecks. B) repeat the analysis process to look for other bottlenecks. C) consider increasing capacity of the bottleneck. D) schedule non-bottleneck resources to support the bottleneck.

b

The third step in Theory of Constraints application, "subordinate all other decisions to Step 2," means that the analyst should: A) wait for authorization before proceeding with any system-wide changes. B) schedule non-bottleneck resources to support the bottleneck schedule. C) seek to increase capacity of only the bottleneck resources. D) seek to increase capacity of both the bottleneck and non-bottleneck resources.

fixed

The traditional method of determining contribution margin does not consider ________ costs.

operational expense

The wages paid to workers on the line are categorized as ________ in the Theory of Constraints.

c

There are three consecutive steps in a customer service process. The first two steps are each capable of serving 25 customers per hour while the third step can process only 20 customers per hour. Which of the following statements regarding this system is TRUE? A) The entire system is capable of processing 25 customers per hour. B) There are floating bottlenecks in the system. C) If the first two steps are run at full capacity, then the third step has a waiting line. D) The first and second steps are bottlenecks for the system.

Question 1 A process consists of steps​ A, B, and C with capacities of 50 units per​ hour, 60 units per​ hour, and 40 units per hour respectively. Which of the following statements is​ best? There should be a small amount of inventory in front of step C. There should be a small amount of inventory in front of step B. If demand is 50 units per​ hour, the manager should try to balance capacity with demand so that steps​ A, B, and C each have a capacity of 50 units per hour. If step A is improved so it can produce one unit per​ minute, the company has saved about 8 minutes per hour.

There should be a small amount of inventory in front of step C.

A bottleneck is an operation that has the lowest effective capacity of any operation in the process.

True

A bottleneck process has the lowest capacity and the longest total time from the start to the finish.

True

A business school with plenty of classroom space that hires adjunct faculty for a semester to meet unusually high student demand for courses is an example of elevating a bottleneck.

True

A mixed-model line produces several items belonging to the same family.

True

Line balancing applies only to line processes that do assembly work, or to work that can be bundled in many ways to create the jobs for each workstation in the line.

True

Line balancing is the assignment of work to stations in a line to achieve the desired output rate with the smallest number of workstations.

True

Operating processes close to their capacity can result in low customer satisfaction and even losing money despite high sales levels.

True

Short term capacity planning should be driven by identification and management of bottlenecks.

True

The Theory of Constraints method is also referred to as the drum-buffer-rope method.

True

The balance delay is the amount by which efficiency falls short of 100 percent.

True

The final step in applying the Theory of Constraints is to repeat the first four steps.

True

The first step in applying the Theory of Constraints is to identify the constraint.

True

The process with the least capacity is called a bottleneck if its output is less than market demand.

True

To generate the maximum output, the cycle time should be set as the longest elemental task time.

True

floating bottlenecks

Variability of a firm's workload may create

a

Which statement about process batches is BEST? A) One or more transfer batches may combine at the constrain buffer to form a process batch. B) A process batch is used to maximize setups at the bottleneck. C) A process batch must be greater than or equal to market demand. D) Process batches are used to increase lead time

d

Which statement about transfer batch sizes is BEST? A) Transfer batches are the same size as process batches when arriving at a bottleneck. B) Transfer batches are the same size as process batches when departing from a bottleneck. C) Transfer batches are a convenient way to increase lead time. D) Transfer batches can be as small as one unit.

d

Work should be released into the system when: A) a customer order is received. B) the first step in the process is idle. C) a customer order is completed. D) the bottlenecks need work.

Question 17 Which Issue below best relates the conversion to a lean production system? Workers can become bored when the current layout is retained and remains fixed. Workers can feel pushed and stressed since the safety net of inventory has been removed. Lean systems require considerable specialization and emphasize each worker retaining one specific job assignment. There is a decrease in the level of trust in a plant once all of the processes have been automated.

Workers can feel pushed and stressed since the safety net of inventory has been removed.

Question 16 Lean Farms operated every process with a lean philosophy. For example once Cletus returned with an empty​ wheelbarrow, Jake knew it was time to get busy shoveling manure in order to fill it back up. This is an example of a container system. a kanban card. a​ poka-yoke. a containerless system.

a container system.

Question 13 The service department of Monroe Brothers Automotive would like to achieve uniform workstation loads. An effective system for this firm would be a reservation system. producing items for inventory when demand is slow. a​ big-lot production. ​single-digit setup.

a reservation system.

Question 12 One of the LEAST effective supplier strategies for lean systems is to include suppliers during the product design phase. ​smaller, more frequent stock shipments. use of local suppliers. a​ short-term, competitive relationship between the company and the supplier.

a​ short-term, competitive relationship between the company and the supplier.

Question 5 The second step in Theory of Constraints​ application, "exploit the​ bottleneck(s)," means that the analyst​ should: consider increasing capacity of the bottleneck. schedule nonminus−bottleneck resources to support the bottleneck. repeat the analysis process to look for other bottlenecks. create a schedule that maximizes the throughput of the bottlenecks.

create a schedule that maximizes the throughput of the bottlenecks.

Question 14 Benefits of having a flexible workforce include all of the following​ EXCEPT: it is easier to relieve bottlenecks. a more uniform work flow. decreased reliance on inventory buffers. decreased worker morale.

decreased worker morale.

Question 19 Continuous improvement with lean​ systems: entails systematically stressing the system and focusing on problem areas. requires periodically increasing lot sizes or workforce levels to uncover problems. involves navigating a ship over treacherous rocks. focuses exclusively on internal operations without addressing relationships with customers and suppliers.

entails systematically stressing the system and focusing on problem areas.

Question 2 Use the process flow diagram to determine which of these events has the greatest net benefit. image 1.PNG increasing the capacity at Station B to 8 units per hour. increasing the capacity at Station C to 7 units per hour. reducing the flow time at Station D from 9 to 8 minutes. reducing the flow time at Station A from 8 to 7 minutes.

increasing the capacity at Station C to 7 units per hour.

capacity

is the maximum rate of output of a process or a system.

throughput time

is the total time taken from the start to the finish of a process.

Question 25 1 / 1 pts At what point in a process is a workstation considered a bottleneck? it has the smallest average capacity. it has the highest total time per unit processed. it has the lowest average utilization. it processes the smallest total workload.

it has the highest total time per unit processed.

Question 10 The pull method is best represented by building it so they will come. farm products. automobile assembly. ​made-to-order computer systems.

made-to-order computer systems.

Question 23 The theory of constraints methods increase the​ firm's profits more effectively by focusing on​ what? eliminating processing variation making materials flow rapidly through the entire system cutting system costs eliminating defects

making materials flow rapidly through the entire system

Question 21 The goal of single−digit setups is to have a setup​ time: of less than one hour. of less than 30 minutes. of less than 10 minutes. of less than one shift.

of less than 10 minutes.

The process batch at the constraint in a drum-buffer-rope system should be:

of such a size as to improve utilization of the constraint.

Question 28 Manufacturing an item before it is needed is an example of what form of​ waste? motion inappropriate processing overproduction underutilization of employees

overproduction

Question 22 Mistake−proofing is known by the​ term: andon. jidoka. muda. poka−yoke.

poka−yoke.

Question 3 Use the process flow diagram to determine which of these events has the greatest net benefit. Station A 1 worker 8 minutes. Station B 1 worker 7 units/hr. Station C 1 worker 6 units/hr. Station D 1 worker 9 minutes. increasing the capacity at Station C to 10 units per hour. reducing the flow time at Station A from 10 to 8 minutes. reducing the flow time at Station D from 12 to 10 minutes. increasing the capacity at Station B to 12 units per hour.

reducing the flow time at Station D from 12 to 10 minutes.

Question 30 1 / 1 pts In lean systems, part commonality serves to increase inventory the number of deliveries needed. repeatability the number of suppliers needed.

repeatability

Question 6 The third step in Theory of Constraints​ application, "subordinate all other decisions to Step​ 2," means that the analyst​ should: wait for authorization before proceeding with any systemminus−wide changes. schedule non−bottleneck processes to support the bottleneck schedule. seek to increase capacity of only the bottleneck resources. seek to increase capacity of both the bottleneck and nonminus−bottleneck resources.

schedule non−bottleneck processes to support the bottleneck schedule.

Question 20 Companies using lean systems generally​ have: suppliers who are lowminus−cost producers. suppliers that are located nearby to decrease delivery lead time. many suppliers to ensure that material shortages never occur. suppliers that are willing to accept shortminus−term contracts.

suppliers that are located nearby to decrease delivery lead time.

Question 24 Of the seven key principles of the theory of​ constraints, which is the first​ principal? maximizing the output and efficiency of every resource is required to maximize the throughput of the entire system the focus should be on balancing​ capacity, not on balancing flow every capital investment must be viewed from the perspective of its global impact product margin the focus should be on balancing​ flow, not on balancing capacity

the focus should be on balancing​ flow, not on balancing capacity

Question 4 Work should be released into the​ system: when the bottlenecks need work. when a customer order is completed. when the first step in the process is idle. when a customer order is received.

when the bottlenecks need work.