A) a push or pull system, depending upon the rate of demand
B) a push system for high margin items and a pull system for low margin items
C) a push system for purchased parts and a pull system for manufactured parts
D) push systems
E) pull systems
A) Employees, machines, and suppliers produce units late.
B) Customer demand is unknown.
C) Employees, machines, and suppliers produce units that conform to standards.
D) Engineering drawings are inaccurate.
E) Drawings or specifications are incomplete.
A) Just-in-time (JIT)
B) Toyota Production System (TPS)
C) Lean operations
D) Material requirements planning (MRP)
E) kanban
A) Just-in-time (JIT)
B) Toyota Production System (TPS)
C) Lean operations
D) Material requirements planning (MRP)
E) kanban
A) Large lots are pulled from upstream stations.
B) Work is pulled to the downstream stations before it is actually needed.
C) Manufacturing cycle time is increased.
D) Problems become more obvious.
E) None of the above is true of a pull system.
A) length of the work shift, expressed in minutes per day
B) time it takes a unit to move from one workstation to the next
C) time between the start of one unit and the start of the next unit
D) sum of all the task times to make one unit of a product
E) time from raw materials receipt to finished product exit
A) Just-in-time (JIT)
B) Toyota Production System (TPS)
C) Lean operations
D) Material requirements planning (MRP)
E) kanban
A) throughput
B) manufacturing cycle time
C) pull time
D) push time
E) queuing time
A) that it takes to process one unit at a station
B) between the arrival of raw materials and the shipping of finished products
C) to produce one whole product through an empty system (i.e., with no waiting)
D) required to move orders through the production process, from receipt to delivery
E) none of the above
A) overproduction
B) transportation
C) assignment
D) defective product
E) motion
A) have the "flavor" of a housekeeping list
B) are a checklist for lean operations
C) have become a list of seven items in American practice
D) can be used to assist with necessary changes in organizational culture
E) All of these are true.
A) identifying non-value items and removing them, in the "sort/segregate" item
B) reducing inventory, in the "standardize" item
C) increasing variability through standardized procedures, in the "standardize" item
D) eliminating wasted motion through ergonomic studies, in the "support" item
E) building good safety practices, in the "shine/sweep" item
A) close relationships with trust
B) close relationships with skepticism
C) distant relationships with trust
D) distant relationships with skepticism
E) none of the above
A) cost reduction
B) variability increase
C) rapid throughput
D) quality improvement
E) rework reduction
A) For incoming goods, receiving activity and inspection are outsourced.
B) In-transit inventory falls as suppliers are located closer to facilities.
C) The number of suppliers increases.
D) In-plant inventory replaces in-transit inventory.
E) All of the above are consequences of meeting the JIT partnership goals.
A) large number of suppliers
B) maximal product specifications imposed on supplier
C) active pursuit of vertical integration
D) removal of incoming inspection
E) frequent deliveries in large lot quantities
A) competitive bidding encouraged
B) buyer plant pursues vertical integration to reduce the number of suppliers
C) support suppliers so they become or remain price competitive
D) most suppliers at considerable distance from purchasing organization
E) All of the above are characteristics of JIT partnerships.
A) removal of in-transit inventory
B) large lot sizes to save on setup costs and to gain quantity discounts
C) long-term contracts
D) few suppliers
E) buyer helps supplier to meet the quality requirements
A) removal of unnecessary activities
B) removal of in-plant inventory
C) removal of in-transit inventory
D) removal of engineering changes
E) All of the above are goals of JIT partnerships.
A) help suppliers meet quality requirement
B) inspect all incoming parts
C) maintain a steady output rate
D) impose maximum product specifications on the supplier
E) draw up strict contracts ensuring that all defectives will be immediately replaced
A) removal of unnecessary activities
B) removal of in-plant inventory
C) removal of in-transit inventory
D) obtain improved quality and reliability
E) All of the above are goals of JIT partnerships.
A) elimination of in-plant inventory
B) delivery to the point of use
C) production with zero defects
D) large lot sizes
E) customers' infrequent engineering changes
A) supplier location near plants
B) low setup costs
C) low carrying costs
D) use of trains, not trucks
E) low-cost, global suppliers
A) desire for diversification
B) poor customer scheduling
C) small lot sizes
D) producing high enough quality levels
E) customers' infrequent engineering changes
A) Suppliers feel that they would be less at risk if they contracted with more than one customer.
B) Suppliers are concerned that customers will present frequent engineering changes with inadequate lead time to deal with them.
C) Suppliers feel that their processes are suited for larger lot sizes than the customer wants.
D) Suppliers are concerned that frequent delivery of small quantities is economically prohibitive.
E) All of the above represent JIT supplier concerns.
A) distance reduction
B) increased flexibility
C) reduced space and inventory
D) cross-trained, flexible employees
E) All of the above are JIT influences on layout.
A) work cells for families of products
B) fixed equipment
C) minimizing distance
D) little space for inventory
E) poka-yoke devices
A) Poka Yoke
B) Pat "Keiretsu" Morita
C) Kanban Polka
D) Shigeo Shingo
E) none of the above
A) It exists just in case something goes wrong.
B) It is the minimum inventory necessary to keep a perfect system running.
C) It hides variability.
D) It is minimized with large lot production.
E) It increases if setup costs decrease.
A) $0.45
B) $4.50
C) $45
D) $450
E) $500
A) $2.00
B) $7.20
C) $18.00
D) $64.00
E) $1,036.80
A) The first step involves performing as much setup preparation as possible while the process/machine is operating.
B) The cycle of steps is repeated until setup time is reduced to under a minute.
C) Standardize tooling and standardize training are included in the same step.
D) Improved material handling and move material closer are done before operator training.
E) All of the above are true.
A) Setup cost must be cut to one fourth its current value.
B) Setup cost must also be cut in half from its current value.
C) Setup cost must double from its current value.
D) cannot be determined
E) none of the above
A) requires that schedules be met without variation
B) processes many small batches rather than one large one
C) is known as "jelly bean" scheduling
D) is based on meeting one day's demand with that day's production
E) All of the above are true regarding level scheduling.
A) The quantities in the containers are usually large to reduce setup costs.
B) It is associated with a push system.
C) It is useful to smooth operations when numerous quality problems occur.
D) The supplier workstation signals the customer workstation as soon as a batch is completed.
E) The customer workstation signals to the supplier workstation when production is needed.
A) small lot sizes
B) signals, such as cards, lights, or flags
C) moving inventory only as needed
D) increased material handling
E) reductions in inventory
A) low inventory
B) employee empowerment
C) card
D) continuous improvement
E) lot size of one
A) A supervisor tells the operators to stay busy and start producing parts for next month.
B) A "supplier" work center signals the downstream workstation that a batch has been completed.
C) A supervisor signals to several work centers that the production rate should be changed.
D) A "customer" work center signals to the "supplier" workstation that more parts are needed.
E) An operator asks the next station's operator to help him fix his machine.
A) close relationship with the restaurant's suppliers of food, utensils, and equipment
B) food preparation in large batches
C) a kitchen set up to minimize wasteful movements
D) lean inventories of food
E) All of the above should be present.
A) one
B) the ratio of the reorder point to container size
C) the same as EOQ
D) one full day's production
E) none of the above
A) not enough information
B) 1
C) 5
D) 10
E) 25
A) Lead time
B) Kanban
C) JIT
D) Kaizen
E) EOQ
A) not enough information
B) 1
C) 5
D) 7
E) 8
A) not enough information
B) 1
C) 5
D) 10
E) 13
A) An empty doughnut tray signaling the bakery to produce 2 dozen glazed doughnuts.
B) A line of 5 people in the Chinese department signaling the department to heat 5 Crab Rangoon.
C) A red light on top of the cashier's lane signals that the cashier needs additional change replenished.
D) The meat department stocking up on turkeys before Thanksgiving.
E) All of the above are kanban applications.
A) Inventory hides bad quality; JIT immediately exposes it.
B) JIT reduces the number of potential sources of error by shrinking queues and lead times.
C) As quality improves, fewer inventory buffers are needed; in turn, JIT performs better.
D) If consistent quality exists, JIT allows firms to reduce all costs associated with inventory.
E) All of the above are true.
A) the cost of low quality can be hidden as inventory cost
B) JIT spots defects early
C) JIT prevents long runs of defects
D) B and C
E) A, B and C
A) UPS drivers are trained to perform several motions smoothly and efficiently.
B) Unionization of the work place brings better morale and therefore better quality.
C) "No one knows the job better than those who do it."
D) all of the above
E) none of the above
A) knowledgeable
B) strict job classifications
C) know more about their job than anyone else
D) empowered
E) All of the above characterize a TPS employee.
A) Total Production Streamlining
B) Toyota Production System
C) Taguchi's Production S's
D) Total Process Simplification
E) None of the above
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