OPM 101 EXAM 1 REVIEW PT2
Costs incurred by defects that occur prior to delivery to the customer are called: external failure costs. internal failure costs. appraisal costs. prevention costs.
internal failure costs.
Which of the following is NOT a core idea of total quality management? cost reduction leadership improvement employee empowerment continuous improvement
cost reduction
Which of the following terms is interchangeable with "lean"? Toyota Production System Value adding Green No waiting
Lean and Toyota production systems are interchangeable
The goal of lean is to ________ from the system. eliminate waste generate value increase output extract profit
Lean's goal is to eliminate waste from the system.
C&A's potato chip filling process has a lower specification limit of 9.5 oz. and an upper specification limit of 10.5 oz. The standard deviation is 0.3 oz. and the mean is 10 oz. What is the process capability index for the chip filling process? 0.33 3.33 0.56 1.11
(USL - LSL)/(6 × Standard deviation) = (10.5 - 9.5)/(6 × 0.3) = 0.555556
Which of the following statements is FALSE? Nonbottleneck resources have a less than 100% utilization. A bottleneck resource must have a utilization of 100%. Nonbottleneck resources have slack capacity. A bottleneck resource does not always have the longest processing time.
A bottleneck resource can have a less than 100% utilization if demand constrained the process.
Which of the following statements is TRUE about capability analyses? A higher process capability index means the process has a lower defect probability A process capability index of 1.33 means that a process has a six sigma capability. A higher process capability index means the process has a higher defect probability. A process must have its mean centered in the middle of its tolerance interval in order to perform capability analyses.
A higher process capability index means the process variation is lower (or higher probability of meeting the tolerance interval) and therefore the defect probability is also lower.
A kanban system ________ work through the process based on ________. pulls, demand pushes, capacity pulls, capacity pushes, demand
A kanban system pulls work through the process based on demand.
The capacity of a nonbottleneck resource is ________ the capacity of the process. equal to The answer depends on the specific process under consideration. smaller than larger than
A nonbottleneck resource has a higher capacity than the bottleneck of the process.
Lean was started as: An offshoot of the quality movement after WWII As Toyota wanted to emulate Ford's efficiencies without huge inventory build-up it saw at Ford. Ford Motor Company turned to mass production in the 1950s Both a and b
As Toyota wanted to emulate Ford's efficiencies without huge inventory build-up it saw at Ford.
A control chart is used to identify ________ of a process. assigned causes of variation input variables output variables normal causes of variation
Assignable causes of variation of a process can be identified as drifts or outliers falling outside the control limits of a control chart.
Job candidates are leaving an office every 50 minutes. Each candidate goes through three activities during the office visit: verification, written test, and interview. Verification takes 1 minute, the written test takes 40 minutes, and the interview takes 10 minutes. Assume there is only one resource dedicated to each activity. What is the utilization of the bottleneck resource? 80% 2% 20% 100%
Cycle time = 50 minutes. Flow rate = 1/50 = 0.02 customer per minute. Bottleneck capacity = Min(1, 1/40, 1/10) = 0.025 customer per minute. Utilization of the bottleneck resource = Flow rate/Capacity = 0.02/0.025 = 80%.
Guests are arriving at a party at a rate of 12 per minute. Each guest will be checked in, served a drink, and accompanied to his/her table by one receptionist, one bartender, and one usher respectively. Both the receptionist and usher can serve 10 guests per minute, whereas the bartender takes 5 minutes to serve one guest. Which resource is the bottleneck and what is the process capacity in guests per minute? Receptionist, 10 Bartender, 5 Usher, 5 Bartender, 0.2
Capacity = 1/Process time. Capacity for both the receptionist and usher = 10 guests per minute. Capacity of the bartender is 1/5 = 0.2 guest per minute. The bottleneck is the bartender because it is the resource with the lowest capacity. The lowest capacity also defines the process capacity, which is 0.2 guest per minute.
Patients are arriving at a clinic at a rate of two per minute. Each patient's visit consists of four steps: check in, record vital signs, receive treatment, and check out. A receptionist takes 1 minute to check a patient in. A nurse takes 2 minutes to record the patient's vital signs. A doctor spends 10 minutes with a patient. A staff member takes 3 minutes to check a patient out. What is the process capacity in patients per hour? 30 6 20 60
Capacity = 1/Processing time. Capacity at check in, record vital signs, receive treatment, and check out is 1, 0.5, 0.1, and 0.3 patient per minute respectively. The lowest capacity is the bottleneck and is Process capacity = 0.1 patient per minute = 0.1 × 60 (minutes/hour) = 6 patients per hour.
Which of the following is NOT a component of worker time on the job? Commuting Non-value-added work Waste Value-added work
Commuting is not a component of a worker's time as it happens outside work.
Which of the following is another name for the fishbone diagram? Pareto diagram Flow diagram Frequency diagram Cause-effect diagram
Fishbone diagrams are also called cause-effect diagrams.
Which of the following is an example of waste of worker intellect? Discounting process improvement ideas from workers Walking from one part of the building to the other Working overtime Taking lunch breaks
Frontline workers are familiar with the work themselves and should be allowed to come up with ideas to improve their work.
Job candidates are leaving an office every 50 minutes. Each candidate goes through three activities during the office visit: verification, written test, and interview. Verification takes 1 minute, the written test takes 40 minutes, and the interview takes 10 minutes. Assume there is only one resource dedicated to each activity. Which of the following conclusions can be drawn? The interview resource is the bottleneck. The process capacity is equal to the bottleneck capacity. The process is demand constrained. The process is capacity constrained.
Process capacity = Min(1, 1/40, 1/10) = 0.025 candidate per minute. Flow rate = 1/Cycle time = 1/50 = 0.02 candidate per minute. The process is demand constrained because the flow rate is less than the process capacity.
Which of the following is a means to counter overproduction? Keep moving things around. Keep resources busy. Produce expected demand. Produce at the volume of actual demand.
Producing exactly the quantity needed to meet demand is a means to counter overproduction.
Which of the following is NOT an element of the Toyota Production System? Kaizen Scientific management Lean Kanban
Scientific management is not an element of the Toyota Production System as it is about following scientific principles of designing work instead of relying on workers' insights.
Which of the following is an example of value-added work? Waiting for customers to order Delivering pizza to customers Taking orders from customers Repairing a defective product
Taking orders from customers is value-added work
Which of the following is the Pareto principle? The majority of problems can be explained by a few root causes. The majority of problems can be explained by many symptoms. The majority of problems can be explained by one root cause. The majority of problems can be explained by many root causes.
The majority of problems can be explained by a few root causes is the Pareto principle.
Which of the following is not a dimension of quality? Performance Conformance Reliability Traceability
Traceability
A worker moving inventory from one machine to another is considered non-value-added work. True False
True
