MG406 Final

Which person was a key figure in developing the Toyota Production System and also developed the concept of poka-yoke? a. Deming b. Toyoda c. Shingo d. Ohno

c. Shingo

Poka-yoke refers to: a. Error- or mistake-proofing b. Reduction of human resources c. Productivity improvement d. None of these choices are correct.

a. Error- or mistake-proofing

Which of the following is NOT consistent with the lean philosophy? a. Increasing batch sizes to take advantage of economies of scale b. Positioning WIP inventories near each processing center c. Developing a culture of continuous improvement within the organization d. Cross-training employees to increase processing flexibility

a. Increasing batch sizes to take advantage of economies of scale

When a process is considered in control, this means that: a. The data plots appear normally distributed around the desired measurement. b. Only natural process variations are present. c. No data plots fall outside the control limits. d. All of these choices are correct.

Only natural process variations are present.No data plots fall outside the control limits.The data plots appear normally distributed around the desired measurement.

calculate the number of inventory containers (round up) required given the following:Demand rate = 12 parts per hour, Safety stock required = 10%Size of containers = 8 parts, Time to cycle through entire system = 4 hours a. 7 containers b. 4 containers c. 5 containers d. 6 containers

[12(4)(1.1)]/8 = 6.6 or 7 rounding up

The Malcolm Baldrige National Quality Award recognizes firms for their quality achievements but is only given to U.S. firms. a. True b. False

a. True

Moving small production batches through a lean production facility is often accomplished using: a. Kanbans b. Lean suppliers c. Keiretsus d. Automation

a. Kanbans

Japanese manufacturing firms sometimes create cooperative coalitions with their suppliers in order to provide the suppliers with a certain degree of financial support. What are these cooperative coalitions called? a. Keiretsu Networks b. Kaizen Networks c. Kanban Networks d. Jidoka Networks

a. Keiretsu Networks

The following is a term that refers to error or mistake proofing: a. Poka-yoke b. Kaizen c. Muda d. Kanban

a. Poka-yoke

When lean firms share their best practices with supply chain members, this is referred to as yokoten. a. True b. False

a. True

According to the Six Sigma philosophy, the Six Sigma goal is to have ____ defects per million measurement opportunities. a. 0 b. 3.4 c. 1.0 d. 9.9

b. 3.4

When purchase order quantities are cut in half, which of the following will be true? a. Average inventory levels will be zero. b. Average inventory levels will also be cut in half. c. Average inventory levels will double. d. Average inventory levels will not be impacted.

b. Average inventory levels will also be cut in half.

Which tool is useful for determining the frequencies of specific problems? a. Fishbone Diagrams b. Check Sheets c. Pareto Charts d. Cause-and-Effect Diagrams

b. Check Sheets

Which of the following quality gurus believed that companies should strive for zero defects and that quality was, in a sense, free since quality improvement programs invariably paid for themselves? a. Deming b. Crosby c. Baldrige d. Juran

b. Crosby

Lean production, JIT, and Six Sigma quality mean the same thing. a. True b. False

b. False

Which company probably played the largest role in the development of the Toyota Production System? a. Chrysler b. Ford c. General Motors d. Boeing

b. Ford

The Five-Ss refer to: a. Robust evaluation techniques b. Industrial housekeeping c. Keiretsu relationships d. Overspending habits

b. Industrial housekeeping

Which of the following is one of the MOST important elements of the lean production philosophy? a. Fully automated assembly lines and a large supplier base b. Inventory reduction and continuous improvement c. Labor reduction and increased lot sizes d. Quality inspections and a standardized product line

b. Inventory reduction and continuous improvement

The Quick Response program, developed in the 1980's, was an offshoot of the following supply chain concept: a. Six Sigma b. Just-in-Time c. Efficient Consumer Response d. Kaisen

b. Just-in-Time

Lean production systems are sometimes referred to as pull systems because demand from customers activates the production actions of the manufacturing facilities. In order for this demand to be communicated to everyone in the supply chain/manufacturing facility a signal must be passed from downstream processing centers to the upstream processing centers. This system of relaying signals is referred to as a: a. Keiretsu Network b. Kanban System c. TQM Network d. Semaphore System

b. Kanban System

In lean terminology, yokoten refers to: a. A signal used to move items through a lean facility. b. Sharing best practices with suppliers and customers. c. Work-in-process in lean facilities. d. The number of containers in a lean facility

b. Sharing best practices with suppliers and customers.

Bill owns Speedy Deliveries and keeps track of customer complaints. For each delivery, there are two possible complaints: a late delivery and a wrong delivery. Bill tracks the delivery "defects" and then uses this information to determine his company's Six Sigma quality level. During the past week, his company made 322 deliveries. His drivers received 8 late delivery complaints and 4 incorrect delivery complaints. What is Bill's defects per million opportunities (DPMO)? a. 4295 b. 644 c. 18634 d. 9377

c. 18634

The Toyota Production System was initially designed based on: a. The continuous improvement system at General Motors. b. Deming's poka-yoke concept. c. Several trips by the Toyoda family to the Ford manufacturing plant. d. The idea of reduction of waste found at General Electric

c. Several trips by the Toyoda family to the Ford manufacturing plant

Attribute data are shown as: a. The number in a sample that met the acceptance standard. b. The number of ounces in a soup can, for example. c. The percent defectives within a sample. d. The mean of a sample's measures.

c. The percent defectives within a sample.

alculate the inventory container size required given the following:Demand rate = 10 parts per hour, Safety stock required = 16%Number of containers = 14, Time to cycle through entire system = 6 hours a. 4 parts b. 3 parts c. 2 parts d. 5 parts

d. 5 parts

Which of the following is an example of how lean programs can help to protect the environment? a. Parts made from recycled materials b. Using rubber from used tires in auto parts c. Batch size reduction to reduce plastics d. All of these choices are correct.

d. All of these choices are correct.

Variations in process measurements can be classified as either natural or: a. Measureable b. Specific c. Unnatural d. Assignable

d. Assignable

An important outcome of statistical process control is: a. Firms can visually monitor process performance b. Firms can minimize total inventory cost c. Firms can take corrective actions before process variabilities get out of control d. Both "Firms can take corrective actions before process variabilities get out of control" & "Firms can visually monitor process performance" e. None of these choices are correct.

d. Both "Firms can take corrective actions before process variabilities get out of control" & "Firms can visually monitor process performance"

How do lean systems impact the environment? a. It means fewer kanbans, which is better for the environment. b. New products are moved to the market more quickly, which is better for the environment. c. It's use of enterprise resource planning means closer ties to the environment. d. It reduces waste, which improves the environment.

d. It reduces waste, which improves the environment.

Which tool is useful for presenting data in an organized fashion, indicating process problems from most to least severe: a. Check Sheets b. Fishbone Diagrams c. Cause-and-Effect Diagrams d. Pareto Charts

d. Pareto Charts

use of Six Sigma helps supply chains become lean, due to: a. The cross-training of employees to increase processing flexibility b. The improved use of Kanbans in production facilities c. The increased batch sizes to take advantage of economies of scale d. The impact that improved quality has on reducing safety stocks

d. The impact that improved quality has on reducing safety stocks

Producer's Risk refers to which of the following scenarios? a. When a buyer rejects a shipment of low quality units because the sample did not meet the acceptance standard. b. When a buyer accepts a shipment of high quality units because the sample did meet the acceptance standard. c. When a buyer accepts a shipment of low quality units because the sample did meet the acceptance standard. d. When a buyer rejects a shipment of high quality units because the sample did not meet the acceptance standard.

d. When a buyer rejects a shipment of high quality units because the sample did not meet the acceptance standard