Question 1

Scott Namos is performing supplier benchmarking for Billings Distribution Company. He notices that capabilities are not matching demands in terms of what actually exists and what should exist. What would be his BEST course of action?

Accepted Answer

When Scott notices capabilities are not matching demands in terms of what actually exists and what should exist, his best course of action would be to perform a gap analysis. Performing a SWOT analysis would not help match capabilities. Performing industry benchmarking would not help with matching demands. Initiating a strategic retreat would be related to strategic planning.

Question 2

In the logistics environment, significant capital investment is made in shipping equipment and facilities. To manage the complex processes of prescheduled pickup and delivery frequency, it would be best to employ use of what?

Accepted Answer

Significant capital investment is made in shipping equipment and facilities. To manage the complex processes of prescheduled pickup and delivery frequency, it would be best to employ use of routing and scheduling software packages. RFID, AS/RS, and Six Sigma would not be the best choice for managing prescheduled pickup and delivery frequency.

Question 3

Internal supply processes include material handling, which is a labor-intensive process in which _____________ is a non-value-added activity?

Accepted Answer

Materials handling is a labor intensive process in which traveling is a non-value-added activity. Sorting, inventorying, and loading are value-added activities, as they are required activities for internal supplies. Traveling is not viewed as a value-added activity for which lean processes should be implemented.

Question 4

In material handling, the best asset tracking system for warehouse inventory monitoring would be which of the following?

Accepted Answer

The best asset tracking system for warehouse tracking would be radio frequency identification devices. Excel databases, hand count, and Kanban indexing would not be as effective as radio frequency identification devices.

Question 5

If your organization has limited warehouse space, only needs small amounts of a product, or needs a wide variety of products for many suppliers, it is most advantageous to use which of the following?

Accepted Answer

If your organization has limited warehouse space, only needs small amounts of a product, or needs a wide variety of products from many suppliers, it is most advantageous to use distributors. This promotes effective use of your warehouse space and eliminates the overhead costs for the storage of product.

Question 6

Planning and scheduling for a lean initiative requires the use of many tools such as affinity diagrams, interrelationship digraphs, tree diagrams, prioritization matrices, matrix diagrams, process decision program (PDPC) charts, and activity network diagrams. To develop a realistic timeline with attainable deadlines which method would be employed?

Accepted Answer

To develop a realistic timeline with attainable deadlines for a project, a PERT analysis would be used to determine probabilistic estimates. A PERT analysis is based on the central limit theorem and the variance is the standard deviation squared. Timeframes are based on the pessimistic time, optimistic time, and most likely time of completion.

Question 7

In the lean environment what does a poka-yoke device prevent or prohibit?

Accepted Answer

In the lean environment a poka-yoke device prevents or prohibits the incorrect execution of a process step. A poka-yoke can be electrical, mechanical, procedural, visual, human, or any other form that prevents the incorrect execution of a step. Poka-yoke helps people and processes work right the first time by building in techniques that make it impossible to make mistakes. These techniques can drive defects out of products and processes and substantially improve quality and reliability. Poka-yoke can be used wherever something can go wrong or an error can be made.

Question 8

An improvement team is performing an analysis on patient wait times in a specialty clinic with multiple clinics using the same waiting area. Which type of queue is in place in this environment?

Accepted Answer

In this environment, the queue type would be service facilities in a series. In this type of queue a customer enters the first station and gets a portion of service and then moves on to the next station, gets some service, moves on to the next station, and finally leaves the system having received the complete service. An example of this flow would be check in, blood lab or urinalysis, see the specialist, radiology imagery, patient leaves.

Question 9

Which design of experiments principle is used to remove systematic error?

Accepted Answer

When using the design of experiments, replication is used to remove systematic error. The number of tests performed should be equal the number of replications. The design of experiments is a systematic series of tests used to determine relationships of x and y variables that affect a process and response. The results of the experiment are analyzed to find the regression equation that relates the factors to the response.

Question 10

Which of these choices is an example of an internal cost related to an improvement?

Accepted Answer

The redesign of a supply warehouse floor layout would be an example of an internal cost. The goal is to have all the costs of quality in the Appraisal and Prevention areas and zero costs of poor quality. Internal cost examples are rework, delays, redesign, shortages, failure analysis, retesting, and downtime. External cost examples are environmental costs, complaints, repairing goods and redoing services, customers' bad will, warranties, and sales losses.

Question 11

Which of these choices is an example of an external cost related to an improvement?

Accepted Answer

Environmental costs for environmental cleanup or abatement would be an example of an external cost related to an improvement. The three types of costs associated with an improvement are internal, external, and prevention. The cost of poor quality is measured differently depending on the industry. Some companies will relate the cost of quality as a percentage of total sales.

Question 12

The Theory of Constraints is the management philosophy of Eliyahu M. Goldratt, where he stated the throughput of the system can be improved with a focused effort to improve the constraint. Which of the following is NOT included in his five steps to improve performance?

Accepted Answer

Develop team focus in the improvement is not included in the five steps to improve performance. The theory of constraints uses five steps to improve performance: 1) Identify the current constraint, 2) Exploit quick improvements to the throughput of the constraint using existing resources, 3) Review all other activities in the process to ensure that they are aligned with and support the needs of the constraint, 4) Elevate if the constraint still exists to consider what further actions can be taken to eliminate it, and5) Repeat the process.

Question 13

The characteristics for control chart monitoring which require monitoring are common causes and special causes. Which of the following is NOT a control chart for special characteristics?

Accepted Answer

A t-chart is not a control chart for special characteristics. The control charts for special characteristics are: x-charts, which plot the behavior of the average level of x; r-charts, which plot the behavior of the variability of x; and bp-charts, which plot the behavior and proportion of items produced that are "defective."

Question 14

In project management, there are four leadership styles in a team approach. Which leadership style aligns with the "supporting" approach?

Accepted Answer

The "supporting" leadership style aligns with the approach where teams require continual support in terms of competencies and experience. The delegating style is useful for teams which are empowered and self-directing. The coaching style is used for those teams on the verge of being self-directed. The directing style of leadership is used for teams which are new or on time-sensitive projects.

Question 15

Which management and planning tool would one use to compare alternative actions or choices when a clear choice is not easily understood or apparent?

Accepted Answer

Prioritization matrices are tools to compare alternative actions or choices when a clear choice is not easily understood or apparent. Prioritization matrices use brainstorming techniques, action planning, and issue analysis, then score the results. Affinity diagrams are used when group consensus is necessary. Interrelationship digraphs are used to show the relationship among factors in a relationship. Matrix diagrams are a planning tool for displaying the relationships among various data sets.

Question 16

Process and design FMEA identifies and evaluates the potential failures of a process, product, or service. How is the risk priority number calculated?

Accepted Answer

The risk priority number is calculated by RPN= severity X occurrence X detection. Any RPN value exceeding 80 requires a corrective action. Severity assesses the impact of the failure mode, with 1 representing the least safety concern and 10 representing the most dangerous safety concern. Occurrence assesses the chance of a failure happening, with 1 representing the lowest occurrence and 10 representing the highest occurrence. Detection assesses the chance of a failure being detected, with 1 representing the highest chance of detection and 10 representing the lowest chance of detection.

Question 17

QFD is used to translate customer requirements to engineering specifications, providing linkage to customers, designers, competitors, and manufacturing. Which of the following is NOT included in one of the steps of QFD?

Accepted Answer

Product life cycle costing analysis is not is not included in one of the steps of QFD. QFD is used early in the design phase using these four steps:1) Product planning to translate customer requirements into the product technical requirements in order to meet them,2) Product design to transfer technical requirements to key product characteristics, 3) Process planning to identify process operations necessary to achieve the characteristics in step 2, and4) Process Control being converted to control operations.

Question 18

When collecting data on the frequency or patterns of problems or defects, the best form of data collection would be which of the following?

Accepted Answer

When collecting data on the frequency or patterns of problems or defects, the best form of data collection would be a process check sheet. A check sheet is a tally sheet that is used to collect data. The other choices are not data collection tools.

Question 19

When selecting and using appropriate sampling methods you must ensure the integrity of data bias. Data bias is a factor in decision making. Which of the following would explain under coverage bias?

Accepted Answer

Under coverage bias would occur when some members of the population are inadequately represented in the sample. Non response bias occurs when individuals chosen for the sample are unwilling or unable to participate in the survey. Voluntary response bias occurs when sample members are self-selected volunteers, as the resulting sample tends to over-represent individuals who have strong opinions. Response bias results from problems in the measurement process due to measurement error.

Question 20

DMADV is a Six Sigma quality initiative for designing products and processes. What are the steps in the DMADV model?

Accepted Answer

DMADV, also known as DFSS, is a Six Sigma quality initiative for designing products and processes. The steps in the DMADV model are define, measure, analyze, design, and verify. It is used for defining new products and processes, as well as optimizing existing ones. It is not be confused with DMAIC, which is used to troubleshoot existing processes.

Quiz 2: Continuous Improvement