BA 341 Exam 2
T/F: If infrequent, large shipments of purchased items are arranged with suppliers, large inventory savings for these items can be realized.
False
A quality circle holds a brainstorming session and attempts to identify the factors responsible for flaws in a product. Which tool do you suggest they use to organize their findings? A. Ishikawa diagram B. control charts C. Pareto chart D. flowchart E. activity chart
a
If a sample of parts is measured and the mean of the measurements is outside the control limits, the process is: A. out of control and the process should be investigated for assignable variation. B. monitored closely to see if the next sample mean will also fall outside the control limits. C. within the established control limits with only natural causes of variation. D. in control, but not capable of producing within the established control limits. E. None of the above.
a
Which one of the following is part of prevention costs? A. The costs of improving process design and product design B. The costs of lawsuits from injury from use of the product C. The costs of quality audits D. The costs resulting from scrap
a
Which one of the following statements is a key feature of both TQM and Six Sigma? A. Quality is primarily the responsibility of all employees in the organization. B. Quality is primarily the responsibility of top management. C. Quality is primarily the responsibility of the quality control department. D. Quality is primarily the responsibility of the production department.
a
A company is interested in monitoring the variability in the weight of the fertilizer bags it produces. An appropriate control chart would be: A. an x-bar chart. B. an r-chart. C. a c-chart. D. a p-chart
b
Companies using lean systems generally have: A. many suppliers to ensure that material shortages never occur. B. suppliers that are located nearby to decrease delivery lead time. C. suppliers that are willing to accept short-term contracts. D. suppliers who are low-cost producers.
b
The list of 5Ss, although it looks like a housekeeping directive, supports lean production by: A. increasing variability through standardized procedures, in the "standardize" category. B. identifying non-value items and removing them, in the "sort/segregate" category. C. building good safety practices, in the "shine/sweep" category. D. eliminating wasted motion through ergonomic studies, in the "support" category. E. reducing inventory, in the "standardize" category.
b
There are many requirements for the successful implementation of the lean system of production. Which one of the following is not such a requirement? A. Short setup time B. Substantial natural resources C. Uniform assembly schedule D. Low machine failure and low defects
b
Weeding out unnecessary items, neatly arranging what's left, and cleaning the work area are components of: A. mixed-model assembly. B. a 5S program. C. a constraint management system. D. a Kanban system.
b
Which of the following attributes is NOT for lean operations? A. Empower employees. B. Build processes that increase variability. C. Develop worker flexibility. D. Develop collaborative partnerships with suppliers.
b
Which of the following is FALSE regarding control charts? A. Control charts are built so that new data can be quickly compared to past performance data. B. Values above the upper control limits imply that the product's quality is exceeding expectations. C. Control charts graphically present data. D. Control charts plot data over time. E. None of the above is false.
b
Which of the following is an illustration of employee empowerment? A. Unionization of the work place brings better morale and therefore better quality. B. "No one knows the job better than those who do it." C. UPS drivers are trained to perform several motions smoothly and efficiently. D. all of the above E. none of the above
b
A production manager at a pottery factory has noticed that about 70 percent of defects result from impurities in raw materials, 15 percent result from human error, 10 percent from machine malfunctions, and 5 percent from a variety of other causes. This manager is most likely using: A. a scatter diagram. B. a quality loss function. C. a Pareto chart. D. a cause-and-effect diagram. E. a flowchart.
c
Combining parts or products with similar characteristics into families and setting machines aside for their production is known as: A. the one-worker, multiple machines (OWMM) method of production. B. the flexible workforce approach to manufacturing. C. group technology. D. the standardized component method of manufacturing.
c
Regarding the Seven Types of Waste that must be eliminated to implement lean systems, which of the following statements is TRUE? A. Work-in-process inventory is the direct result of underutilization of employees. B. Product damage and deterioration result from using expensive high precision equipment. C. Jobs with excessive motion should be redesigned. D. Manufacturing an item before it is needed helps an organization detect and reduce defects.
c
Using customer demand to activate production of an item or service is called: A. the andon method. B. the jidoka method. C. the pull method. D. the push method.
c
Which of the following is NOT an attribute of lean operations? A. minimizing space requirements by reducing the distance a part travels B. eliminating almost all inventory through just-in-time techniques C. pushing responsibility to the highest level possible through centralized decision making D. educating suppliers to accept responsibility for helping meet customer needs E. building worker flexibility through cross-training and reducing job classifications
c
Which of the following would be a "common" cause of variation? A. An untrained worker B. A machine in need of repair C. Random sources D. A defective raw material
c
Which step of the Six Sigma DMAIC procedure monitors the process to make sure high performance levels are maintained? A. Define B. Analyze C. Control D. Measure E. Improve
c
A grocery store is attempting to implement a kanban system. Which of the following would NOT be an application of kanbans? A. A line of 5 people in the Chinese department signaling the department to heat 5 Crab Rangoon. B. A red light on top of the cashier's lane signals that the cashier needs additional change replenished. C. An empty doughnut tray signaling the bakery to produce 2 dozen glazed doughnuts. D. The meat department stocking up on turkeys before Thanksgiving. E. All of the above are kanban applications.
d
In lean systems, if a defective product is found, which of the following is generally NOT done? A. The defective unit is returned to the worker responsible for creating the defect. B. The production line is stopped. C. The production line is made aware of the problem without necessarily stopping the line. D. The defective unit is passed on to the next workstation.
d
Justin Thyme used to run one batch each of 500 As, 300 Bs and 100 Cs every month but now he runs a batch of 5 As, 3 Bs, and 1 C every half day: A. now that he has andon lights installed at the appropriate work centers. B. in order to increase muda. C. thanks to his employer's move away from single-digit setups. D. now that he embraces mixed-model assembly.
d
Lead time for computers is 7 days with daily demand of 5 computers and a safety stock of 1 day. Each kanban holds 8 computers. What is the correct number of kanbans? A. 4.5 B. 8 C. 1 D. 5 E. 7
d
Lean systems use the standardization of components because standardization: A. decreases the demand for each component. B. decreases repeatability. C. allows for small lot sizes more easily. D. increases repeatability.
d
Management at Pepman has decided to switch from a push system to a pull system of manufacturing. They are a large repetitive manufacturer of bicycles. Which one of the following is most likely to occur? A. The space required will increase due to the increase in the number of units that require rework. B. The cycle time will increase, resulting in higher inventory levels. C. The workers at any given process will produce units before they are needed by the subsequent process. D. The decrease in WIP inventory levels will reduce the space requirements.
d
The objective of a statistical process control (SPC) system is to A. assess customer expectations. B. eliminate natural variations. C. provide a statistical signal when natural causes of variation are present. D. provide a statistical signal when assignable causes of variation are present.
d
When considering the plan-do-check-act cycle for problem solving, instructing other employees in the use of the new process occurs in the ________ step. A. do B. plan C. check D. act
d
Which of the following is NOT a Lean inventory tactic? A. reduce lot size B. reduce setup time C. use group technology D. use a push system to move inventory
d
Which of the following is not one of Taiichi Ohno's seven wastes? A. queues B. motion C. transportation D. energy
d
Which one of the following is an advantage of lean systems? A. Lean systems can be implemented in any production environment. B. Lean systems reduce equipment needs by using larger lot sizes. C. Lean systems result in an increase in manufacturing lead times. D. Lean systems result in a decrease in safety stock and work-in-process inventory.
d
Which one of the following statements is TRUE about the kanban system? A. It is associated with a push system. B. The supplier workstation signals the customer workstation as soon as a batch is completed. C. It is useful to smooth operations when numerous quality problems occur. D. The customer workstation signals to the supplier workstation when production is needed. E. The quantities in the containers are usually large to reduce setup costs.
d
Lead time for cakes is 2 days with daily demand of 10 cakes and a safety stock of 1/2 a day. Each container (kanban) holds 1 cake. What is the correct number of kanbans? A. 10 B. 1 C. 5 D. 4 E. 25
e
Techniques for building employee empowerment include: A. building high-morale organizations. B. moving responsibility from both managers and staff to production employees. C. developing open, supportive supervisors. D. building communication networks that include employees. E. All of the above are techniques for employee empowerment.
e
Which of the following is TRUE regarding the steps to reducing setup times? A. The cycle of steps is repeated until setup time is reduced to under a minute. B. The first step involves performing as much setup preparation as possible while the process/machine is operating. C. The standardization of both tooling and work procedures is advantageous to setup time reduction. D. Move material closer and improve material handling are done before operator training. E. All of the above are true.
e
Which one of the following scenarios represents the use of a kanban to reduce inventories? A. A supervisor signals to several work centers that the production rate should be changed. B. An operator asks the next station's operator to help him fix his machine. C. A supervisor tells the operators to stay busy and start producing parts for next month. D. A "supplier" work center signals the downstream workstation that a batch has been completed. E. A "customer" work center signals to the "supplier" workstation that more parts are needed.
e
Just-in-time systems make demands on layouts, including the need for: A. increased flexibility. B. cross-trained, flexible employees. C. distance reduction. D. reduced space and inventory. E. all of the above
e
