Deck 7: Quality and Process Improvement

Question 1

Companies have adopted various slogans to describe initiatives to develop lean systems. Which one of the following slogans would not be consistent with the philosophy of lean systems?

A) hidden inventory
B) material as needed
C) synchronous manufacturing
D) stockless production

Answer 1

hidden inventory

Question 2

Which one of the following competitive priorities is most often emphasized in JIT production?

A) low cost
B) high- performance design
C) product flexibility
D) volume flexibility

Answer 2

low cost

Question 3

Companies utilizing JIT systems generally have

A) suppliers who are low- cost producers.
B) suppliers that are located nearby to decrease delivery lead time.
C) suppliers that are willing to accept short- term contracts.
D) many suppliers to assure that material shortages never occur.

Answer 3

suppliers that are located nearby to decrease delivery lead time.

Question 4

Which of the following is not an element of JIT practices?

A) specialized workers
B) pull method
C) uniform production rates
D) quick setups

Question 5

Which of the following would not be present, for a family dining restaurant, implementing JIT and lean production?

A) small food inventories
B) close relationship with restaurant's suppliers
C) food preparation in large batches
D) kitchen arranged to minimize wasteful movements

Question 6

There are many requirements for the successful implementation of the JIT system of production. Which one of the following is not such a requirement of the JIT system?

A) short setup time
B) uniform assembly schedule
C) low machine failure and low defects
D) substantial natural resources

Question 7

When implementing a JIT system,

A) it is critical to develop a master production schedule that changes frequently as forecasts change.
B) management should base the reward system on production volume.
C) the plant layout is the only environmental characteristic that need not be analyzed.
D) managers can mitigate some of the effects of worker stress by judiciously using safety stocks and emphasizing material flows rather than worker pace.

Question 8

JIT systems maintain inventory in small lot sizes because small lot sizes

A) increase the quality level of the product.
B) increase pipeline inventory, allowing the organization to buffer against demand uncertainties.
C) enable schedules to utilize machine capacities more efficiently.
D) increase manufacturing lead time because of the increase in waiting time.

Question 9

Which one of the following statements is TRUE?

A) Two operating rules for the kanban system are (1) the container size should be equal to at least seven days of supply and (2) each container must have a kanban card.
B) The kanban system is more effective when the assembly schedule calls for small lots and does not fluctuate much from day to day.
C) Supplier performance is much more important in U.S. environments than such factors as lot sizes, scrap losses, and worker flexibility.
D) The number of kanban cards should be equal to the desired safety stock times alpha.

Question 10

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

A) A kanban and a container move as a pair once production begins at the fabrication process.
B) An empty container can be exchanged for a full container at the storage location even though no kanban is on the full container.
C) A typical kanban used in the JIT system includes various information such as item number, unit price, competitor's product name, and its price.
D) A kanban can be used to set the order quantity, but not the inventory level.

Question 11

Use the information in Table 8.3. How many kanban containers would be required if a 5 % efficiency factor is used?

A) 10 or less
B) 11 or 12
C) 13 or 14
D) 15 or more

Question 12

A supplier to a company using JIT II

A) will incur increased invoicing and payment costs but will get higher prices.
B) enjoys a savings in personnel costs because the in- plant representative is employed by the customer.
C) will be able to sell directly to the engineering department of the customer.
D) must be very flexible to incur the dramatic swings in requirements from the customer.

Question 13

When a push system is replaced by a pull system, with smaller lot sizes, many benefits can be realized. Which one of the following statements correctly represents one of these benefits?

A) Only simple planning systems are required.
B) More space is required to keep the increased amount of WIP inventory.
C) The inventory level is increased to protect the system from the uncertainty in demand.
D) Cycle time will be increased, resulting in higher machine utilization.

Question 14

Of the following statements, which one is most characteristic of a JIT system of production?

A) high dependence on customized components, as in high variability in components
B) large lot sizes to achieve uniform operating system workloads
C) high conformance to product or service quality specifications
D) high variability in the daily loads for individual workstations

Question 15

When mixed model scheduling is used on an assembly- line

A) JIT is not possible.
B) nonuniform workload will result in the feeding of work centres.
C) a uniform workload will result in the feeding of work centres.
D) large lot sizes are the result.

Question 16

The just- in- time (JIT) philosophy is about

A) a comprehensive approach to eliminate waste.
B) improving quality by selecting certified suppliers.
C) reducing cost by reducing the number of suppliers.
D) improving delivery performance by doing all operations ahead of time.

Question 17

Which of the following statements about using JIT systems for services is FALSE?

A) Preventive maintenance can be important for a service.
B) Unlike manufacturing, there is little need for analyzing work methods because services are typically customized.
C) The need to develop a flexible workforce is a function of the degree of customization of the services provided.
D) Reservation systems can be used to provide uniform facility loads.

Question 18

The customer in a company that uses JIT is considered what?

A) the customer
B) defined as the end user
C) the next person or machine to use or further the current process
D) seldom needed to evaluate the quality of the finished product

Question 19

When a push system is replaced by a pull system using small lot sizes, which one of the following is expected to happen?

A) More units will be reworked to fix a quality problem.
B) WIP will increase.
C) More space will be required for inventory.
D) Cycle time will decrease.

Question 20

Which one of the following is not one of the characteristics of JIT systems?

A) close supplier ties
B) large batch sizes to provide a cushion of inventory
C) consistently high conformance quality
D) pull method of material flows

Question 21

Which of the following is not an example of the pull method of material flows?

A) a flooring contractor that only stocks samples of products, ordering supplies from manufacturers once customers place orders
B) replenishing inventory in a retail outlet based on forecast demand
C) Dell Computers make- to- order system for fulfilling orders placed through its on- line retailing site
D) selecting the toppings for a pizza based on specific customer orders

Question 22

Which of the following would not be a benefit of small production lots?

A) smaller work- in- process inventory
B) workstations can be closer together
C) shorter manufacturing cycle time
D) fewer setups

Question 23

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

A) specialized workforce
B) longer setup times
C) uniform assembly schedules
D) high rates of machine failures

Question 24

Use the information in Table 8.1. How many kanban containers would be required if a 10 % efficiency factor is used?

A) 3 or less
B) 4 or 5
C) 5 or 6
D) 7 or more

Question 25

The advantages of JIT systems include all but which one of the following?

A) reduction in machine utilization
B) increase in productivity
C) reduction in space requirements
D) reduction in inventory

Question 26

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

A) management system of people and procedures to fulfill all delivery deadlines.
B) integrated system of managing resources, information, and decision processes to eliminate waste.
C) materials management system for removing all inventories.
D) production system of small- lot manufacturing to reduce work- in- process inventory.

Question 27

All of the following wastes but one often occur in the firms.

A) Overproduction
B) Defects
C) Motion
D) Overutilization of employees

Question 28

The final assembly schedule in a JIT system

A) allow daily changes in demand levels, regardless of size, to be incorporated immediately into the work center schedules.
B) should be developed for each product independent of the process requirements for the other products.
C) strives to create a uniform flow at the work centers in the plant.
D) avoids the use of small lot sizes because they create many production orders and cause confusion.

Question 29

Implementing a JIT system

A) requires an examination of the reward system to make sure it is consistent with the JIT philosophy.
B) has the advantage that workers have less stress because of the routine, repetitive work they perform.
C) involves the reorganization of material flows to that of a flexible flow.
D) typically relieves the workers and first- line supervisors from activities such as scheduling, expediting, and productivity improvements.

Question 30

Use the information in Table 8.1. Using an efficiency factor of 5 %, calculate the number of kanban containers needed for the fastener.

A) 3 or less
B) 4 or 5
C) 5 or 6
D) the next person or machine to use or further the current process 7 or more

Question 31

Use the information in Table 8.2. How many kanban containers would be required if a 10 % efficiency factor is used?

A) 3 or less
B) 4 or 5
C) 5 or 6
D) 7 or more

Question 32

Use the information in Table 8.3. How many kanban containers would be required if a 15 % efficiency factor is used?

A) 10 or less
B) 11 or 12
C) 13 or 14
D) 15 or more

Question 33

In a JIT II system the

A) sales effort of the supplier increases but the cost of materials to the customer decreases.
B) customer need not have close interaction with the supplier.
C) customer is brought into the plant as an active member of the purchasing department of the supplier.
D) in- plant representative replaces the buyer, salesperson, and sometimes the materials planner.

Question 34

In JIT systems, if a defective product is found, which of the following is generally NOT done?

A) The defective unit is returned to the worker responsible for creating the defect.
B) The production line is made aware of the problem without stopping the line.
C) The defective unit is passed on to the next workstation.
D) The production line is stopped.

Question 35

Suppliers often cite which of the following as a major concern?

A) long- term contracts
B) minimization of inventory
C) large lot sizes
D) zero defect production

Question 36

According to JIT, an approach to reduce product variation is

A) make fewer setups.
B) continually improve the process.
C) hire and train quality inspectors.
D) by many competing sources.

Question 37

Which of the following are not a characteristic of just- in- time / lean systems?

A) large order sizes to earn quantity discounts
B) inbound transport scheduling
C) few suppliers
D) long- term contracts

Question 38

Early shipments to a company utilizing a JIT system result in

A) decreased production costs for the company.
B) stockouts for the company.
C) back orders for the company.
D) extra inventory for the company.

Question 39

Which one of the following is not a characteristic of JIT systems?

A) empowerment of employees
B) on time quality deliveries
C) strong job specialization
D) training

Question 40

Use the information in Table 8.2. How many kanban containers would be required if a 5 % efficiency factor is used?

A) 3 or less
B) 4 or 5
C) 5 or 6
D) 7 or more

Question 41

Which of the following statements regarding a pull system is true?

A) Work is pulled to the downstream stations before it is actually needed.
B) Manufacturing cycle time is increased.
C) Problems become more obvious.
D) Large lots are pulled from upstream stations.

Question 42

JIT systems utilize the standardization of components because standardization

A) decreases the demand for each component.
B) allows for small lot sizes more easily.
C) decreases repeatability.
D) increases worker productivity.

Question 43

Use the information in Table 8.3. How many kanban containers would be required if a 10 % efficiency factor is used?

A) 10 or less
B) 11 or 12
C) 13 or 14
D) 15 or more

Question 44

Continuous improvement with JIT systems

A) entails systematically stressing the system and focusing on problem areas.
B) requires periodically increasing lot sizes or workforce levels to uncover problems.
C) involves navigating a ship over treacherous rocks.
D) focuses exclusively on internal operations because relationships with customers and suppliers are addressed by the logistics department.

Question 45

________ refers to the goal of having a setup time of less than 10 minutes.

Question 46

Which of the following will result if the goals of JIT partnerships are met?

A) Inventory in transit is replaced by on- site inventory.
B) As suppliers are located closer to facilities, in- transit inventory decreases
C) Receiving activity and inspection are outsourced for incoming goods.
D) The number of suppliers increases.

Question 47

Mixed model production requires

A) computer scheduling.
B) special- purpose equipment.
C) unfocused factories.
D) multiskilled workers.

Question 48

Which one of the following is not a benefit of the implementation of JIT?

A) quality improvement
B) reduction in work in process
C) variability increase
D) cost reduction

Question 49

A(n) ________ is a JIT concept that results in material being produced only when requested and moved to where it is needed just and only as it is needed.

Question 50

The just- in- time production system is a total system concept that takes cultural environment, managerial practice, and support of the workforce into account. Which one of the following statements regarding the basic philosophy of JIT systems is TRUE?

A) For managers, a high level of inventory is regarded as the main resource that they can utilize for flawless operation of the manufacturing system.
B) One of the few disadvantages of a JIT system is the large storage area requirement for inventory.
C) The JIT system eliminates buildup of inventories by coordinating the flow of materials between processes.
D) Sufficient amounts of natural resources are the main element for the successful implementation of JIT systems.

Question 51

Which of the following is generally not accepted as a JIT action, when a manufacturer took the following actions to reduce inventory?

A) inventory in transit has been reduced
B) a pull system was introduced to move inventory
C) production of smaller lots was introduced
D) the lowest priced, based on quantity discounts, supplier is chosen

Question 52

Any deviation from the optimum process that delivers perfect product on time, every time, is ________ .

Question 53

With respect to quantities, which characteristic of JIT partnerships would be included of the following?

A) suppliers ship based on their own production schedules
B) short- term contracts to ensure flexibility
C) a variable output rate
D) supplier is packaging in standard quantities

Question 54

The ________ is the minimum inventory necessary to keep a perfect system running?

Question 55

With respect to JIT systems, what is the advantage of standardized components?

Question 56

Although small lot sizes are beneficial to operations, they have the disadvantage of increasing the frequency of ________ .

Question 57

What is a kanban?

A) used in a push system
B) a card
C) authorization of equipment maintenance
D) designed for a job shop

Question 58

Which one of the following is an advantage of just- in- time (JIT) systems?

A) JIT systems reduce equipment needs by using larger lot sizes.
B) JIT systems result in a decrease in safety stock and work- in- process inventory.
C) JIT systems can be implemented in any production environment.
D) JIT systems result in an increase in manufacturing lead times.

Question 59

For firms along the supply chain, two aspects of lean systems that are important to manage include ________ and ________ .

Question 60

The main focus of lean systems in implementing JIT is the reduction of investment in inventory and requires _________ .

Question 61

The Japanese word for card that has come to mean "signal" is ________ _.

Question 62

Daily production schedules in high volume, make- to- stock environments must be ________
for extended periods.

Question 63

What are the advantages of producing in small lots?

Question 64

The standardization of components, called part commonality or ________ , increases repeatability which supports lean production.

Question 65

Explain how a line flow strategy can be used to reduce or eliminate setups.

Question 66

In lean systems, workers and first- line supervisors must take on ________ formally assigned to middle managers and support staff.

Question 67

________ is the philosophy that waste can be eliminated by cutting unnecessary inventory and removing non- value- adding activities in operations.

Question 68

What are the organizational issues companies must address before implementing a JIT system?

Question 69

The ________ method produces the item when activated by customer demand.

Question 70

Suppliers accept responsibility for helping to meet customer's needs due to ________ .

Question 71

The ________ method produces the item in advance of customer need.

Question 72

A(n) ________ assembly line produces a mix of models in smaller lots.

Question 73

When suppliers are encouraged to locate near manufacturing plants, the goal of the JIT partnership is to reduce ________ inventory.

Question 74

The 5S term referring to organization of the work area so that it easy to find what is needed, would be ________ .

Question 75

A(n) ________ is a card used to control the flow of production through a factory.

Question 76

JIT suppliers have concerns that the JIT firm's demands for small lot sizes are simply a way of transferring holding cost from manufacturer firm to the supplier firm.

Question 77

What is the "pull method" of material flow?

Question 78

In lean systems, small lot sizes are required, resulting in a large number of setups, which means companies must significantly reduce _________ .

Question 79

________ are operating systems that are designed to create efficient processes by taking a total systems perspective.

Question 80

________ is a system where the supplier is brought into the plant to be an active member of the purchasing office of the customer.