TOM 301 Ch. 8

10. Which of the following is an example of wasted flow time? A. A long waiting time at checkout B. Idle time of cashier C. Merchandise returned to the store D. Ringing up sales at the register

A. A long waiting time at checkout

26. Which of the following statements about wasting time of a flow unit is TRUE? A. By reducing the waiting time of a flow unit, the time it takes to turn inputs into output is decreased. B. The process flow diagram shows where and why a flow unit spends time in a process. C. The value-added time of a flow unit is equal to its takt time. D. Holding everything constant, an increase in flow time improves the extent to which an operation is considered lean.

A. By reducing the waiting time of a flow unit, the time it takes to turn inputs into output is decreased.

41. Which of the following process changes is NOT needed to implement ikko-nagashi? A. Implementing a push system B. Operating on takt time C. Leveling demand D. Transferring units piece by piece

A. Implementing a push system

28. Which of the following can be used to uncover a waste of flow time? A. Inventory level B. Overall equipment effectiveness C. Labor content D. Overtime

A. Inventory level

37. ____________ means to produce in the amounts needed, when needed, and where needed using a single unit flow. A. Just-in-time B. Built-in quality C. Process improvement D. Stable environment

A. Just-in-time

54. Which of the following terms refers to fool-proofing an operation to avoid the recurrence of defects? A. Poka-yoke B. Automation C. Heijunka D. Andon

A. Poka-yoke

18. Which of the following is NOT an element of the Toyota Production System? A. Scientific management B. Kaizen C. Lean D. Genchigenbutsu

A. Scientific management

13. Which of the following is an example of value-added work? A. Taking orders from customers B. Repairing a defective product C. Delivering pizza to customers D. Waiting for customers to order

A. Taking orders from customers

56. What is the relationship between the number of Kanban cards in a process and the inventory level? A. There is no more inventory in the process than was authorized via Kanban cards. B. The inventory of the process grows with the square root of the number of Kanban cards. C. The inventory of the process is reduced by adding more Kanban cards. D. There is no relationship between the two.

A. There is no more inventory in the process than was authorized via Kanban cards.

19. Which of the following statements about sources of production waste is FALSE? A. Working overtime is a waste because it means more labor cost is spent on a flow unit than necessary. B. Rework is a waste because resources are spent to correct mistakes instead of adding value. C. Waiting is a waste because resources are not fully utilized. D. Over-processing is a waste because it means more time is spent on a flow unit than necessary.

A. Working overtime is a waste because it means more labor cost is spent on a flow unit than necessary.

25. Wastes of flow time become visible by taking the perspective of the _________. A. flow unit B. management C. supplier D. labor content

A. flow unit

40. The benefits of a smooth single unit flow include all of the following EXCEPT: A. more inventory. B. easier process improvement. C. shorter flow times. D. faster feedback.

A. more inventory.

38. _________ means to detect and address defects when and where they occur and prevent them from recurring. A. Just-in-time B. Built-in quality C. Process improvement D. Stable environment

B. Built-in quality

22. Which of the following is an example of waste of worker intellect? A. Walking from one part of the building to the other B. Discounting process improvement ideas from workers C. Working overtime D. Taking lunch breaks

B. Discounting process improvement ideas from workers

44. Which of the following is a way to implement a pull system? A. Make to stock B. Make to order C. Make to capacity D. Make to inventory

B. Make to order

32. Which of the following is NOT one the 4Ps of Toyota production system? A. People B. Profit C. Processes D. Philosophy

B. Profit

11. Which of the following terms is interchangeable with "lean"? A. Value adding B. Toyota Production System C. Green D. No waiting

B. Toyota Production System

7. Lean operations is about reducing two forms of waste, wasted _______ and wasted ________. A. inventory, capacity B. capacity, flow time C. inventory, flow time D. inventory, time

B. capacity, flow time

42. In a pull system, an information flow of external demand is moving ___________ and the physical flow of the flow units is moving ____________. A. downstream, upstream B. upstream, downstream C. upstream, upstream D. downstream, downstream

B. upstream, downstream

34. The Toyota Production System is often depicted as a house. The roof of TPS consists of ___________ and _____________. A. waste reduction, profit maximization B. waste reduction, matching supply and demand C. built-in quality, matching supply and demand D. built-in quality, just-in-time

B. waste reduction, matching supply and demand

12. Which of the following is NOT a component of worker time on the job? A. Waste B. Value-added work C. Commuting D. Non-value-added work

C. Commuting

46. Which of the following statements about ikko-nagashi is TRUE? A. It is about optimizing transfer batch size with a given process layout. B. It is the same as a kanban system. C. It is about having flow units flow one-unit-at-a-time from one resource to the next. D. It is about organizing work flow by function or equipment.

C. It is about having flow units flow one-unit-at-a-time from one resource to the next.

21. Which of the following statements is FALSE regarding overall equipment effectiveness (OEE)? A. OEE identifies what percent of a resource's time is spent on value-added work. B. OEE is part of a productivity analysis of a resource. C. OEE can exceed a value of one. D. OEE identifies the portion of a worker's time which is being wasted.

C. OEE can exceed a value of one.

48. Which one of the following is a consequence of uneven workflow? A. Multiple job assignments B. No idle time in the production process C. Overburdening of workers and equipment D. Just-in-time production

C. Overburdening of workers and equipment

17. Which of the following is NOT one of the seven sources of waste? A. Inventory B. Overproduction C. Waste of management time D. Movement

C. Waste of management time

9. The goal of lean is to ____________ from the system. A. extract profit B. increase output C. eliminate waste D. generate value

C. eliminate waste

36. The Toyota Production System can be represented in the shape of a ___________. A. boat B. box C. house D. pyramid

C. house

53. The key concepts that characterize TPS's approach towards root cause problem solving are _________ and _________. A. kaizen and jidoka B. genchigenbutsu and jidoka C. kaizen and genchigenbutsu D. kaizen and zero inventory

C. kaizen and genchigenbutsu

50. TPS's quality improvement involves all of the following EXCEPT: A. avoid recurrence. B. detect-stop-alert. C. kanban. D. root cause analysis.

C. kanban.

35. The Toyota Production System is often depicted as a house. The foundation of TPS consists of ___________ and ____________. A. waste reduction, just-in-time B. process improvement, just-in-time C. process improvement, stable processes. D. waste reduction, process improvement.

C. process improvement, stable processes.

24. The following are sources of wasting time of a flow unit EXCEPT: A. storage times. B. transportation times. C. processing times. D. setup times.

C. processing times.

29. The value-added percentage is defined as _________ divided by __________. A. value-added time of a flow unit, available time B. available time, value-added time of a flow unit C. value-added time of a flow unit, flow time D. flow time, value-added time of a flow unit

C. value-added time of a flow unit, flow time

14. The overall equipment effectiveness framework identifies what percentage of a resource's time is _________ and what percentage is _________. A. available time, value-added time B. equipment time, labor time C. value-added time, wasted time D. available time, wasted time

C. value-added time, wasted time

30. A lean operation strives to achieve a reduction of ___________ and ____________ simultaneously. A. demand in capacity, available time B. demand in capacity, flow time C. waste in capacity, flow time D. waste in capacity, available time

C. waste in capacity, flow time

55. Which of the following statements about Toyota production system is TRUE? A. An Andon cord that is rarely pulled is a good indicator of success of TPS implementation. B. Implementing TPS amounts to selecting the right lean tools to use. C. TPS is only relevant for manufacturing operations. D. All dimensions of TPS need to be adopted by an organization in order to get the full benefits of lean.

D. All dimensions of TPS need to be adopted by an organization in order to get the full benefits of lean.

8. Which of the following is NOT an example of wasted capacity? A. Idle time B. Rework C. Setup D. Flow time

D. Flow time

52. C&A uses a line of 5 stations to make a product. The cycle time is 30 seconds per unit. The inventory between stations is 10 units. Inspection happens at the end of the process. Which of the following is NOT a way to shorten the information turnaround time for a defect made at station 2? A. Reduce the amount of inventory between stations. B. Reduce cycle time. C. Inspect at every station. D. Increase the number of stations after station 2.

D. Increase the number of stations after station 2.

27. Which of the following can NOT be used to determine the extent to which an operation is lean? A. Inventory turns B. Value-added percentage C. Overall equipment effectiveness D. Labor content

D. Labor content

23. Which of the following is a means to counter overproduction? A. Keep resources busy. B. Keep moving things around. C. Produce expected demand. D. Produce at the volume of actual demand.

D. Produce at the volume of actual demand.

39. __________ means a process has a smooth flow with little variability. A. Just-in-time B. Built-in quality C. Process improvement D. Stable process

D. Stable process

15. Which of the following is the idea behind genchigenbutsu? A. Work should be designed by engineers. B. Improvement of work can only come from management. C. Work can be designed by those who are not fully familiar with the process. D. Workers should be the ones observing and improving a process.

D. Workers should be the ones observing and improving a process.

33. The Toyota Production System is often depicted as a house. The two pillars of the TPS are ___________ and ____________. A. waste reduction, just-in-time B. process improvement, just-in-time C. waste reduction, built-in quality D. built-in quality, just-in-time

D. built-in quality, just-in-time

20. To avoid rework is to: A. do it at the right time. B. do it right using the longest time. C. do it right using the shortest time. D. do it right the first time.

D. do it right the first time.

43. A kanban system ____________ work through the process based on _________. A. pushes, capacity B. pulls, capacity C. pushes, demand D. pulls, demand

D. pulls, demand

57. In the Toyota Production System, jidoka refers to: A. Level production, where different models are produced alongside each other on the assembly line B. Continuous improvement, where workers organize meetings to discuss ways of improving the production process C. The inventory retrieval system where parts are replenished only when they are needed D. The aggressive reduction of changeover and setup times E. None of these are correct

E. None of these are correct

The Japanese term used in the Toyota Production System to mean automation with a human touch. The concept has been generalized to include any mechanism that stops production in response to quality problems.

Jidoka