Ops Exam 3 Pearson Questions

Manufacturing an item before it is needed is an example of what form of​ waste?

overproduction

In lean​ systems, part commonality serves to increase

repeatability

One of the LEAST effective supplier strategies for lean systems is

a short-term, competitive relationship between the company and the supplier

Line flows are recommended in designing lean system layouts because they eliminate waste by reducing

The frequency of setups

The service department of Monroe Brothers Automotive would like to achieve uniform workstation loads. An effective system for this firm would be

a reservation system

Lean systems can be an integral part of a corporate strategy based on speed as they improve what factors?

cycle times, labor productivity, & inventory turnover

What is a major reason why a traditional labor contract may cripple a​ company's ability implement​ lean?

t reduces the​ company's ability to reassign workers to other tasks as the need arises

(T or F) In manufacturing​ systems, one way to achieve continuous improvement can be to maintain low​ inventories, and periodically cut safety stocks almost to zero.

True

The​ just-in-time (JIT) system is​ a(n):

integrated system of managing​ resources, information, and decision processes to eliminate waste.

Regarding the Eight Types of Waste that must be eliminated to implement lean​ systems, using expensive high precision equipment when a simpler machine would suffice is part of which general waste​ category?

inappropriate processing

(T or F) Long production​ runs, poor material​ flows, and processes that are not tightly linked to one another can cause over​ 90% of a​ product's lead time to be spent waiting.

True

Regarding the Eight Types of Waste that must be eliminated to implement lean​ systems, manufacturing an item before it is needed is part of which general waste​ category?

overproduction

Continuous improvement with lean​ systems:

entails systematically stressing the system and focusing on problem areas

(T or F) In the push method of​ workflow, customer demand activates the production of a good or service.

False

​(T or F) Just-in-time (JIT) systems rely on inspectors to inspect quality into the product.

false

(T or F) Five S practices can enable workers to visually see everything​ differently, prioritize​ tasks, and achieve a greater degree of focus.

true

Companies using lean systems generally​ have:

suppliers that are located nearby to decrease delivery lead time

Lean systems maintain inventory in small lot sizes because small lot​ sizes:

enable schedules to use machine capacities more efficiently

The lean system concept will not work without the proper environment. Which one of the following characteristics is most common to firms that have successfully implemented a lean​ system?

uniform assembly schedules

Using customer demand to activate production of an item or service is​ called:

the pull method

Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is known​ as

Jidoka

Designing shipping boxes to be packed only in a certain way to minimize damage and eliminate all chances of mistakes is an example​ of

poka-yoke

Combining parts or products with similar characteristics into families and setting machines aside for their production is known​ as

group technology.

The method that groups products with similar characteristics into families and sets aside groups of machines for their production is called

group technology

Benefits of having a flexible workforce include all of the following​:

decreased reliance on inventory buffers, a more uniform work flow, it is easier to relieve bottlenecks

A kanban system is an important mechanism for lean system management. Which one of the following statements regarding the operation of a kanban system is​ best?

A kanban and a container move as a pair once production begins at the fabrication process.

An important mechanism for lean systems is a kanban system. Which one of the following statements correctly describes the behavior of a​ two-card kanban​ system?

Containers must never be removed from the storage location without an authorizing withdrawal kanban.

Which one of the following statements regarding the Toyota production system is​ best?

faster processing time for the part held by the container

Which of the following is NOT characteristic of a kanban​ system?

it serves as a push mechanism

Lean Farms operated every process with a lean philosophy. For example once Cletus returned with an empty​ wheelbarrow, Jake knew it was time to get busy shoveling manure in order to fill it back up. This is an example of

a container system

In the context of lean​ systems, what best defines the primary role of a Kanban​ system?

it serves as a visual tool to track inventory levels & trigger replenishment

(T or F) Lean systems require large batch sizes to gain economies of scale.

False

Which of the following is a process consideration in the implementation of a lean​ system?

firms might have to change existing layouts

Which one of the following is an advantage of lean​ systems?

Lean systems result in a decrease in safety stock and​ work-in-process inventory.

Lean systems can be an integral part of a corporate strategy based on speed as they improve which processes?

cycle times, inventory turnover, labor productivity

Lean systems coupled with statistical process control​ (SPC) requires a high degree of regimentation which in turn can lead to

worker stress

Which of these issues is a problem associated with the conversion to a lean production​ system?

Workers can feel pushed and stressed since the safety net of inventory has been removed.

Which of the following best characterizes JIT​ systems?

pull method of materials flow

The ability to automatically detect the occurrence of an​ abnormality, thereby helping achieve quality at the​ source, is

Jidok

Which of these terms is NOT one of the Five​ Ss?

store

The theory of constraints methods increase the​ firm's profits more effectively by focusing on​ what?

making materials flow rapidly through the entire system

Of the seven key principles of the theory of​ constraints, which is the first​ principal?

the focus should be on balancing flow, not on balancing capacity

If during week 1 the mix of work makes operation 1 a​ bottleneck, and the next week it may makes operation 3 the​ bottleneck, the variability in workload has created a

floating bottleneck

Bottlenecks exist in which type of manufacturing​ processes?

line, job, & batch processes

What is the name of the product mix decision method that produces the products with the highest contribution margins and ignores fixed​ costs?

the traditional method

The theory of constraints defines inventory as

all the money invested in a system in purchasing things that it intends to sell

An item that has been built to stock has yet to be sold. Which TOC operational measure is used to describe it in its current​ state?

inventory

what is the management philosophy that identifies the most significant limiting factor that stands in the way of achieving a goal and then systematically improves that constraint until it is no longer the limiting factor.

The theory of constraints

The focus for a process improvement exercise should be on​ balancing:

flow

Work should be released into the system​ when:

when the bottlenecks need work

The third step in Theory of Constraints​ application, "subordinate all other decisions to Step​ 2," means that the analyst​ should:

Schedule non-bottle neck processes to support the bottleneck schedule

A workstation in a process is a bottleneck if

it has the highest total timer per unit processed

The theory of constraints principles outlined are applicable to what type of​ processes?

large service processes, large hospital processes, large manufacturing processes

the total elapsed time from the start to the finish of a job being processed at one or more workcenters.

throughput time

(T or F) A bottleneck process has the lowest capacity and the longest total time from the start to the finish.

true

(T or F) The key to managing bottlenecks is to bypass the bottleneck step in the process.

False

In a​ drum-buffer-rope system, the lot size that moves from one work center to another for additional processing is​ a(n):

transfer batch

The process batch at the constraint in a​ drum-buffer-rope system should​ be:

of such a size as to improve utilization of the constraint

Which statement about process batches is​ BEST?

One or more transfer batches may combine at the constrain buffer to form a process batch

In a DBR​ system, the mechanism that controls the rate at which the bottleneck dictates the throughput of the entire plant is called the

Rope