AP 2 Section 4 Part D

Upon recognizing an uncertainty of the value streams that generate customer value, a company's first step should be to a. Document all value streams across the entire organization and then share findings with all involved b. Consolidate all IT systems under one company-wide enterprise resource planning system c. Hire experienced consultants to assist d. Train key employees in value stream mapping

a. Document all value streams across the entire organization and then share findings with all involved

The three components of sustainability are a. Economic, Environmental, Social b. Social, Environmental, Regulatory c. Social, Economic, Regulatory d. Economic, Environmental, Ecological

a. Economic, Environmental, Social

The element of flexibility most related to the number of kanbans in the system is a. Having short internal setup times that permit frequent changeover b. The ability of a work center to match the required output rate c. Having a certification program that ensures operator cross-training d. The ease with which movable equipment allows a layout to be reconfigured

a. Having short internal setup times that permit frequent changeover

Which of the following approaches to managing engineering changes is the most disruptive to manufacturing? a. Holding all changes until the product is in production b. Including the supplier in engineering change decisions c. Introducing changes during prototype runs d. Establishing an engineering change committee

a. Holding all changes until the product is in production

To focus on customer needs, a company should implement a. House of quality b. Concurrent engineering c. Six sigma d. Lean Manufacturing

a. House of quality

A company wants to lower costs on products purchased from a single source supplier. The most effective way to accomplish this is to a. Jointly eliminate waste in the product and share the savings b. Automate the purchasing process c. Use facilitators to lead the price negotiations d. Identify competitor prices to use as incentives

a. Jointly eliminate waste in the product and share the savings

A supplier receipt has been rejected due to a sampling inspection process. What should production ask the quality department to do in order to keep the material plan valid? a. Perform 100% inspection on enough units to satisfy known demand b. Accept the lot and perform 100% inspection to identify the rejected parts c. Request the material be replaced by another qualified supplier d. Expedite new replacement materials to the original required date

a. Perform 100% inspection on enough units to satisfy known demand

Which of the following scenarios are most indicated in a participative design environment? a. Product design is performed in parallel with process design b. Parts are low in cost and lead time, and high in quality c. Standard parts are used in order to reduce inventory costs d. Product designs are lowest in cost due to combined engineering

a. Product design is performed in parallel with process design

Which of the following tools is used to translate customer needs into product features? a. Quality function deployment (QFD) b. Process map c. Critical-to-quality characteristics (CTQs) d. Pareto chart

a. Quality function deployment (QFD)

Which of the following manufacturing technology choices would most likely provide the greatest benefit to a company whose order winners are delivery speed and flexibility? a. cellular manufacturing system b. quality function deployment c. automated material handling d. transfer line

a. cellular manufacturing system

Pulling together a cross functional team to drive new product design is an example of a. concurrent engineering b. project management c. good manufacturing practices (GMP) d. backward integration

a. concurrent engineering

A program useful in bringing a new product to market faster is: a. concurrent engineering. b. critical to quality characteristics (CQC). c. focused factory. d. kaizen blitz.

a. concurrent engineering.

A satisfactory quality average used during sampling inspection is called: first pass yield. acceptable quality level (AQL). first article inspection. perceived quality.

acceptable quality level (AQL).

Early customer involvement in the design process can result in Key performance indicators Lower training costs A longer product life cycle Improved manufacturability

A longer product life cycle

When a failure becomes external, four viable mitigation options include Apologizing, refunding, reworking, providing compensation Replacement, rework, refund, dinner meeting with purchasing agent Refunding, replacing, reworking, threating a lawsuit Refunding, reworking, replacing, canceling all business

Apologizing, refunding, reworking, providing compensation

Which of the following actions is an effective way to use supplier partnerships? Use the supplier partnership to renegotiate prices Reduce the procurement department due to less work Assist suppliers with cost saving initiatives and share the savings Determine which suppliers will receive annual awards

Assist suppliers with cost saving initiatives and share the savings

Conveyors used as part of an assembly operation should be At an ergonomic height Controlled by systems Simple and inexpensive A replacement for indirect labor

At an ergonomic height

The parts per million defect target level for a company pursuing six sigma is: a. 6 b. 3.4 c. 0 d. 2

b. 3.4

In order to better serve its customer needs, a manufacturer wants to change the design of one of its products, while minimizing time to market. This could best be accomplished with a. New product design b. Concurrent engineering c. Research and development d. Six sigma

b. Concurrent engineering

Mitigation of an out-of-control internal manufacturing process must follow the path of a. Hiring more quality personnel b. Fact finding, education, and empowerment, observe, adjust and repeat.. c. Use the supplier of the raw materials as the temporary scapegoat d. Hiring a public relations consultant

b. Fact finding, education, and empowerment, observe, adjust and repeat..

A company that transitions from sequential product development to concurrent engineering typically experiences which of the following outcomes? I. Better fit of products to production capabilities II. Increased influence by manufacturing engineering over design decisions III. Reduced variety of product components a. I and II only b. I and III only c. II and III only d. I, II, and III

b. I and III only

A way for a company to prevent the failure of a new product release with missed dates or quality / performance issues is to a. Deliver early versions of the product or service to a friendly customer for testing and feedback b. Include a prototype build and test process step into the new product release schedule. c. Construct the process so that design engineering builds the first few saleable lots of end item product d. Release the product for sale as soon as possible to keep the pressure on manufacturing

b. Include a prototype build and test process step into the new product release schedule.

A quality-designed product will help prevent which of the following situations? a. Competitive pricing b. Increased service-related costs c. Lot traceability issues d. The need for continuous improvement

b. Increased service-related costs

Single minute exchange of die is most associated with a. Single minute exchange of tooling in assembly b. Internal setup activities moved to external setup c. Internal setups performed in one minute or less d. Scheduling the process to be down for ten minutes during setup

b. Internal setup activities moved to external setup

A company's sustainability strategy first has an impact on a. Employee training b. Product and process design c. Recycling of by-products and co-products d. Employee attrition

b. Product and process design

To mitigate a potential catastrophic failure, companies may resort to executing a. Backward integration plans b. Risky company life or death plans c. Forward integration plans d. A new round of stock buyback programs

b. Risky company life or death plans

One method to increase machine utilization is to a. Reduce lot sizes b. Run orders with similar setup together c. Run the largest quantity orders first d. Increase preventive maintenance time

b. Run orders with similar setup together

The purpose of using flow path lines on a process flow chart is a. Solid lines indicate the primary path and dashed lines indicate alternate routings b. The lines graphically differentiate among value and non value-added processes c. The lines ensure that no reverse flows or pseudo operations exist in the process d. The line weight represents the cost of non value-added operations

b. The lines graphically differentiate among value and non value-added processes

At one time a high-end automobile had 97 components. After an out-of-the-box evaluation, the number was reduced to 7 parts. This part reduction is a key goal of a. concurrent engineering b. design for manufacturability c. benchmarking d. Supplier rationalization

b. design for manufacturability

Corrective actions are defined as: a. adjustments to inventory balances based on cycle counts. b. implementation of solutions to reduce or eliminate problems. c. changes to the general ledger to fix incorrect entries. d. discipline of employees for non-conformance.

b. implementation of solutions to reduce or eliminate problems.

A part has a historical yield of 99%. What quantity should be started in order to produce 1000 parts? a. 1010 b. 990 c. 1000 d. 1011

d. 1011

Which of the following performance measure areas is excluded from any measure of variance? a. Efficiency b. Actual run time c. Utilization d. External setup time

d. External setup time

Producing a consistently high-quality product requires which of the following actions? a. Implementing preventive maintenance. b. Using automated inspection equipment. c. Increasing the amount of sampling. d. Focusing on an error-free process.

d. Focusing on an error-free process.

Long-term agreements with suppliers may include which of the following terms? I. Required quantities II. Ownership exchange points III. Supplier held inventory IV. Models of transportation a. IV only b. II and III only c. I, II, and III only d. I, II, III, and IV

d. I, II, III, and IV

Which of the following considerations are necessary when selecting suppliers to be a major part of a supply chain? I. The technical capability to work on effective product designs II. Annual sales patterns and financial stability III. An ability to communicate quickly and easily a. I and II only b. I and III only c. II and III only d. I, II, and III

d. I, II, and III

Reducing lead time has which of the following results? a. Increased fixed manufacturing costs b. Decreased fixed manufacturing costs c. Shorter planning cycles d. Increased responsiveness to customer demand

d. Increased responsiveness to customer demand

Engineering has suggested that a company's products would provide more value to customers if they were capable of identifying and automatically reporting problems to service and repair associates. The most likely effect of this strategy would be a. To enhance the product's order qualifying features b. More frequent on-site service thus increasing costs overall c. A marketing feature that will facilitate moving selling prices higher d. Increasing customer up time, reducing customer repair costs

d. Increasing customer up time, reducing customer repair costs

A supplier that provides 100% acceptable quality products is providing a. Statistical quality control b. Quality Function Deployment c. Perceived quality d. Quality at the source

d. Quality at the source

The voice of the customer process is in complete alignment with a. The Delphi method b. Process flow analysis methodology c. Qualitative forecast techniques d. Quality function deployment

d. Quality function deployment

Which of the following methodologies would be most appropriately used during the design of a new product to ensure that it meets the customer needs? a. Concurrent engineering b. Quality at the source. c. Early supplier involvement (ESI) d. Quality function deployment (QFD)

d. Quality function deployment (QFD)

If a company's design cycle is less than that of its competitors, which of the following statements would most likely be true? a. The forecasting horizon will be shorter b. The product's life cycle will be longer c. The competitor's product will have more features d. The company's products will reach the market sooner

d. The company's products will reach the market sooner

Which of the following bottleneck performance measures is as meaningful in a make-to-order environment with a functional layout as it is in a make-to-stock environment with a flow layout? a. Lot size b. Efficiency c. Setup time d. Utilization

d. Utilization

Locating a customer-owned area within a supplier's facility enables the ability to achieve a. No improvements at all on quality metrics b. A significant savings in energy costs c. Significant abilities in changing mix SKU's at the last minute d. Very high performance scores on order delivery key performance indicators

d. Very high performance scores on order delivery key performance indicators

The best way for a company to reduce the cost of quality and improve customer satisfaction is to: a. increase finished product inspection. b. establish a customer warranty program. c. perform regular customer surveys. d. reduce process variability.

d. reduce process variability.

Group technology may be used to identify the physical similarity of manufactured parts. A major benefit of this would be to facilitate identification of obsolete parts design modifications formation of a dedicated manufacturing cell modularity

formation of a dedicated manufacturing cell

A design method that identifies the physical similarity of parts and provides for rapid retrieval of existing designs is: taguchi methodology. group technology. design for the environment. design of experiments.

group technology.

Getting the right goods or services to the right place at the right time and in the desired condition" best defines: logistics. procurement. operations management. supply chain management.

logistics.

The use of U-lines promotes all of the following outcomes EXCEPT: production in a batch at each machine. more effective utilization of labor. reduction of inventory between operations. visibility of problems related to quality.

production in a batch at each machine.

Ensuring all customer needs are identified in an effort to solidify the product design is an example of the Delphi method quality function deployment (QFD) process process flow analysis methodology qualitative forecast technique

quality function deployment (QFD) process

The design methodology most relying on the voice of the customer as well as cross functional input from the organization is: design for production. quality function deployment. total quality management. quality design.

quality function deployment.

A company with customer-specific configurations can minimize the impact of demand changes by achieving flexibility in Lot sizes Inventory levels Delivery lead times Changeovers

Changeovers

Cooperation between partners within a supply chain can best be achieved by setting up multiple channels of Quality checks Communication Reporting Transportation

Communication

Which of the following actions provides visibility of flow in a lean production environment? a. Displaying performance measures over time in the work areas. b. Installing lights to warn people of approaching robotic vehicles. c. Attaching large parts-identification tags to containers. d. Posting customer complaints.

Displaying performance measures over time in the work areas.

Which of the following statements about supplier rating systems is true? a. Suppliers who achieve the lowest price should be rewarded. b. They should be mandatory for all suppliers. c. They should be used only when suppliers do not perform to expectations. d. Goals should be mutually agreed upon.

Goals should be mutually agreed upon.

Which of the following techniques combines product design parameters, customer needs, and a competitive assessment? Force field interrelationships Interrelationship diagram House of quality Matrix chart

House of quality

By implementing a supplier certification program, a company should be able to eliminate Incoming inspection for parts from the supplier Quality audits of the supplier Safety stock Receiving paperwork

Incoming inspection for parts from the supplier

End-of-line inspection often fails to improve quality for which of the following reasons? It excludes quality circles. It disregards the causes of poor quality. Inspectors do not understand quality improvement techniques. It requires extensive personnel.

It disregards the causes of poor quality.

Visual management supports continuous improvement in which of the following ways? It supports formal systems to identify opportunities. It ensures supervisory control of information. It supports group understanding of goals. It simplifies the steps in process improvement.

It supports group understanding of goals.

The purpose of first article inspection is to verify the product's Manufacturability Functionality Sustainability Process variability

Manufacturability

The quality function deployment (QFD) process can be facilitated with a process known as voice of the customer (VOC) horizontal integration vertical integration group technology analysis

voice of the customer (VOC)

Most organizations build a scorecard using Key Performance Indicators (KPIs) to track and share transportation performance. Some of these KPIs migh include: a. Delivery consistency, cost of service, units per transaction b. On-Time delivery, delivery consistency, cost of service c. Inventory turnover, delivery consistency, back order rate d. On-Time delivery, delivery consistency, back order rate

On-Time delivery, delivery consistency, cost of service

Certification of suppliers enables a company to take advantage of what kind of stocking location? Floor stock Point of use Random Automated storage retrieval

Point of use

Universal power supplies that can be set to different voltages based on the country the customer resides in is a sample of Concurrent design Decoupling Curve fitting Postponement

Postponement

Variability refers to a characteristic of Standards Processes Causes Statistical process control

Processes

Having suppliers that are certified via ISO9000 or some other quality standard means Processes are defined and followed Single source relationships can now be established Suppliers fully understand customer needs Product quality is assured

Processes are defined and followed

A company aware that their processes are suboptimal cannot initiate improvement until a. Those employees who do not agree with the concept are fired b. A crisis of grand proportions reveals the true need for improvement c. Employee financial incentives are introduced d. Processes are documented, value streams identified and shared with representatives from all departments

Processes are documented, value streams identified and shared with representatives from all departments

Increasing yield of a product reduces Product cost Kanban size Finished goods inventory Queue time

Product cost

Production orders are riskiest to dispatch without knowing Equipment availability Operator availability Information availability Purchased part availability

Purchased part availability

The House of Quality is part of which of the following processes? Supplier quality assessment Statistical process control Quality Function Deployment Acceptable quality level

Quality Function Deployment

Which of the following techniques would provide the most comprehensive evaluation when designing a new product? Prototyping Consumer surveys Benchmarking Quality Function Deployment

Quality Function Deployment

Quality Function Deployment is an example of Total Employee Involvement Cost of quality Reduction of variability Quality at the Source

Quality at the Source

Waste at the supplier can be eliminated by using Acceptance sampling Quality at the source Vendor-managed inventory Joint replenishment

Quality at the source

Method Cost/load # of days Rail 450 10 Truck 750 4 Air 900 2 LTL 700 6 A company is determining the least cost means of moving product to a distribution center. Using the information provided, what the least expensive method? Air Rail LTL Truck

Rail

Machine utilization can be increased by Reducing lot sizes Increasing efficiency Reducing unplanned downtime Increasing product changeovers

Reducing unplanned downtime

Which of the following activities is a reportable occurrence by production? Repair of existing equipment Downtime for tooling change New equipment installation Preventive maintenance

Repair of existing equipment

A company is performing a quality audit on a supplier that is process-oriented and has an excellent reputation. The company should audit which concept at the supplier? Maintainability Capability Repeatability Flexibility

Repeatability

A fault tree analysis may also be described as which of the following types of analyses? Post-failure Potential cause Risk mitigation Operations resilience

Risk mitigation

When using a six sigma problem solving approach, problems are identified using Statistics Financials Brainstorming Observations

Statistics

The focus of Hoshin planning is on developing which of the following? Training procedures Future employee skills requirements Definitions of standard work Strategies to address critical business needs

Strategies to address critical business needs

Changing plant layout to a manufacturing cell arrangement to attain faster plant throughput requires Extra capacity available Sufficient demand for product Pull system in place Supplier delivery direct to work center

Sufficient demand for product

A company has made process improvements that reduced shift lengths from 10 to 8 hours while maintaining production rates and material delivery schedules. What is the general effect on the level of raw material? It reduces by 20% It increases by 20% There is no change It reduces by 25%

There is no change

An effective way to improve the capability of production process equipment is Performing 100% inspection on assemblies Using design of experiments (DOE) Applying drum-buffer-rope Moving internal setup to external setup

Using design of experiments (DOE)

The processes of creating, producing, and delivering a good or service to the market is a Business-to-business commerce Logistics Cumulative lead time Value stream

Value stream

A supplier has access to a customer's inventory data and is responsible for maintaining the inventory level required by a customer. The vendor reviews inventory on-site at the customer's location, restocks, and then invoices the customer. The inventory is termed: Cycle inventory Consignment inventory Fluctuation inventory Vendor-managed inventory

Vendor-managed inventory

Design of Experiments (DOE) is used to plan a test to determine clothes whitening by three laundry detergents on three types of washing machines. Which of the follow is the dependent variable in the experiment? Washing time Person conducting the experiments Laundry detergent Whiteness factor

Whiteness factor

An effective quality process for product design includes which of the following activities? a. Analyzing the product or service's sensitivity to the environment b. Determining the split of appraisal vs. prevention costs c. Ensuring the design is complex enough that it cannot be duplicated by competitors d. Aligning design features with demographic data for sales information

a. Analyzing the product or service's sensitivity to the environment

Mean time to repair (MTTR) is the average time: a. between failures. b. of all part repairs. c. of the part repair. d. to get a technician on site.

c. of the part repair.

A key benefit of using certified suppliers is Eliminating the need for price negotiation Eliminating the need for incoming inspection Reducing purchasing lead times Receiving the best possible price for the goods

Eliminating the need for incoming inspection

As a product or service matures, the organization's collective knowledge of risk prevention and mitigation will a. Cause the complete elimination of all risks for all products and services b. Prevent all intrusions to the facility from any regulatory agency c. Facilitate reduction in both errors of commission and omission d. Successfully eliminate all existing risks associated with that product or service

c. Facilitate reduction in both errors of commission and omission

Which of the following results are goals of quality function deployment (QFD)? I. Achieving statistical process control II. Understanding customer needs and wants III. Optimizing product and process designs a. I and II only b. I and III only c. II and III only d. I, II, and III

c. II and III only

Which of the following techniques should be introduced to reduce the cost of processing transactions? Larger order quantities, backflushing and kanbans Backflushing, supplier certification and kanban Larger order quantities, backflushing and supplier certification Larger order quantities, supplier certifications and kanbans Which of the following outcomes are benefits of implementing group technology? I. Reduced need for employee training II. Increased product variety III. Lower work-in-process inventories IV. Reduced manufacturing lead time a. I and IV only b. II and III only c. III and IV only d. I, II, III, and IV

c. III and IV only

A direct handoff from one operation to the next such as a customer and supplier located in the same facility will a. Be the root cause of complacency if the customer is always satisfied thus preventing improvements within the process b. Likely result in close employee friendships thus leading to an overall reduction in the quality of the finished products c. Naturally increase quality levels of finished products d. Likely result in additional arrangements this becoming quite complex from a competitive perspective

c. Naturally increase quality levels of finished products

Which of the following quality performance measures is most important to be reported from production? a. Number of receipts accepted b. Offline quality related to rework c. Number of receipts rejected d. In process common cause quality

c. Number of receipts rejected

Attribute sampling has rejected a lot of 200 of a purchased part. There is an immediate need for 50 items for the current week, and 50 more the following week. The supplier has indicated that a new shipment can be made in two weeks for 200 units. Which of the following actions should be recommended by the quality department? a. Return the material and expedite a replacement quantity b. Reject the material and update the supplier-part record accordingly c. Perform 100% inspection until 100 acceptable items are obtained d. Return the material and add a 2-week safety lead time to future orders

c. Perform 100% inspection until 100 acceptable items are obtained

Production becomes less synchronous the lower in a bill of material the part is due to a. Bills of material typically excluding floor stock at lower levels b. Machining and assembly occurring in batch to reduce setups c. Successive lot quantities decoupling demand from supply d. Cumulative lead times introducing a measure of variability

c. Successive lot quantities decoupling demand from supply

Which of the following statements is true about companies that begin to automate before implementing lean production? a. They tend to have a higher success rate. b. They find that the conversion to lean production goes faster. c. They tend to spend more money on material handling. d. They find that the conversion to automation goes faster

c. They tend to spend more money on material handling.

A quality management technique that measures controllable and uncontrollable process variables and their effects on managing satisfactory outputs from the process is called: a. design for manufacturability. b. design for the environment. c. design of experiments. d. design for quality.

c. design of experiments.