Operation Management ChPt 8

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. Kanban System b. Semaphore System c. Keiretsu Network d. TQM Network

a. Kanban System

Which of the following is NOT one of the Seven Wastes? a. Excess inventory b. Environmental waste c. Waiting d. Scrap and rework

b. Environmental waste

If lot sizes are reduced by 50 percent, what impact will this have on average inventory levels? a. Increase by 50% b. Increase by 100% c. Decrease by 25% d. Decrease by 50%

d. Decrease by 50%

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

c. Just-in-Time

Calculate 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. 2 parts b. 3 parts c. 4 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 the above

d. All of the above

Waste in Japan is also referred to as: a. Muda b. Kanban c. Poka-yoke d. Sakichi

a. Muda

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

a. Pareto Charts

Efficient Consumer Response was initially developed in the 1990's for the following industry: a. Fashion b. Grocery c. Small Electronics d. Automobile

b. Grocery

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. Jidoka Networks b. Keiretsu Networks c. Kanban Networks d. Kaizen Networks

b. Keiretsu Networks

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

c. Ford

When compared to their U.S. counterparts, a benchmarking study found that Japanese auto manufacturers used: a. Twice the manufacturing labor b. Double the manufacturing space c. Half the engineering hours to produce a new automobile model d. All of the above

c. Half the engineering hours to produce a new automobile model

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

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

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

c. Industrial housekeeping

Calculate the defects per million opportunities (DPMO) given the following: Blake, owner of Blakester's T-shirt Shoppe, keeps track of customer complaints. For each T-shirt sold, there are four possible complaints: T-shirt shrinks, poor quality, design wears off, and doesn't fit right. Each week, Blake calculates the rate of T-shirt "defects" per total T-shirts sold, and then uses this information to determine his company's DPMO. During the past week, his company sold 1200 T-shirts. His company received 22 customer shrinkage complaints, 16 poor quality complaints, 12 design wears off complaints, 8 doesn't fit right complaints. Calculate his firm's DPMO. a. 69,600 b. 0.193 c. 5.8 x 106 d. 12,083

d. 12,083

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

d. Both A & B

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. Juran b. Deming c. Baldrige d. Crosby

d. Crosby

Lean production emphasizes all of the following EXCEPT: a. Continuous improvement b. Reduction of waste c. Synchronization of material flows d. Long production runs

d. Long production runs

Which of the following layouts is primarily designed to process parts, components, or jobs requiring the same or similar processing steps, saving duplication of equipment and labor: a. Work centers b. Production kanbans c. Work-in-process d. Manufacturing Cells

d. Manufacturing Cells

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

d. Shingo

Which of the following are among the MOST important elements of the lean production philosophy? a. Quality inspections and a standardized product line b. Fully automated assembly lines and a large supplier base c. Large inventories and quality inspections d. Waste reduction and continuous improvement

d. Waste reduction and continuous improvement