ITEC 4023 CHPT ALL QUIZZES|QUESTIONS AND ANSWERS|100% CORRECT|LATEST 2025 UPDATE WITH COMPLETE SOLUTION

ITEC 4023 CHPT ALL QUIZZES|QUESTIONS AND ANSWERS|100% CORRECT|LATEST 2025 UPDATE WITH COMPLETE SOLUTION A value Steam mapping analysis can identify optimization scope of the process True False One should understand following by Lean Lean is a type of manufacturing or services process Lean means eliminating waste Lean means advanced manufacturing systems Lean means eliminating waste to create value for customer Identify features of value streams from the following processes Correct Answer VSM identifies linkages between information and materials flow Correct! It identifies inventory waste You Answered It identifies most efficient operation steps Correct! Identifies the inferior steps that need improvement Customer needs PULL enterprise activities means Lean is customer focused It is creating a rule for quickest delivery Means PULL helps in scheduling activities Means PULL helps in overall enterprise planning to improve bottom line The primary purpose of organization Specify what customer wants Making money to comply with regulatory requirements to motivate employees to perform better The core idea of Lean is eliminating waste only True False One of the lean enterprise features : Making highestt possible profit for enterprise stakeholders Making employees aware of their benefits Line up value creating activities in best sequence Keep the enterprise financially sound. Which of the following is not an objective of Value Stream mapping? Providing a big picture view of a process Balancing the requiremnts Providing training on lean approach Identifies reasons for waste Value Stream creates value so Only value added activities are included in value Stream It does not include no value added activies It includes both value and non value added activities It eliminates non value added activities so, only value added activities are there Knowing about Muda or waste may be considered one of the fundamental The statement is not true Since waste is related to the fundamentals of lean, the statement is true Lean means elimination of waste , so the statement may be considered true Statements 2 and 3 are correct Statement 1 is the correct answer Lean approach can not be used in manufacturing systems In services systems Educational system planning Lean approach can be applied in all of the above cases Customer requirements may be considered a PULL True False To fill in the gaps select right answer: Mass production ------- driven, lean------- driven Profit, customer Profit, cost Correct Answer Expert; workforce efficiency , PULL # 3 right choice Which of the following is not a Lean Fundamental Demand is created by customer pull Companies make the value to flow Creating customer value Customer satisfaction A value Stream is streams of processes and products can identify unnecessary process steps is intended to create value by involving an effective team of people is a tool to improve production quality only Lean approach cannot be applied in financial systems, because it follows a structured approach based on a company rule True False The following may be the differences between Lean Product and TQM. Select the most correct answer. Lean addresses customers needs and wants but TQM mainly addresses on the Quality management systems Lean focuses on improving a firm's processes continuously by identifying and eliminating wastes TQM focuses on building capability to address customer's needs and wants. Lean focuses mainly on customer satisfaction by eliminating waste but TQM focuses mainly on building capability for quality None of the above are correct What differentiates Competitiveness for Industrial companies? Select most correct answer. They differentiate the way they design and build the product. Paying attention to what customers want. Adopting manufacturing philosophy that is more agile? Addressing all the points in the answers 1, 2, and 3 Who instituted the management philosophy that complement the Mass production system introduced by Ford? Select the correct answer from the following. Ford Alfred Sloan William Durant None of the answers are correct? What distinguishes Lean companies from traditional companies? Select the most correct answer for this questions from the following Making things , better, cheaper, faster and becoming more agile? Making things with attractive features and cheaper Becoming agile to address market requirements in minimum amount of time Eliminating waste from the overall process and becoming customer friendly The Value Stream Manager is accountable for: Ensuring that the value stream meets or exceeds customer requirements Improving the ratio of value added time to the total lead time Eliminating waste in the overall supply chain of the product family from start to finish All of the above None of the above Takt time can be calculated by dividing the amount of customer sales by the effective working time. True False A value-added activity can be described as: Any activity that increases the function of the product or service Any activity that the customer is willing to pay for Both of the above None of the above Overproduction is processing a product than required by the next process. earlier more faster All of the above A leveling box or a heijunka box is used for: Leveling the machine so that the slides of the machines operate well Scheduling the machine Leveling the inventory levels around the machine. None of the above. The ideal for the %(VAT/NVAT) ratio is 100%. True False To derive the cycle time for a process: Divide the processing time for the pieces processed on the machine by the number of pieces processed in one cycle Divide the processing time by the Takt time Divide the Takt time by the processing time None of the above is true When continuous flow of product in a facility is restricted, the option is to use: FIFO channels Supermarket Kanban All of the above In creating a value stream map, the idea is to reduce inventory and eliminate lead time. True False Value stream improvement places emphasis on reducing or eliminating non- value added efforts in the . entire system the work cell the operations the set up system Which of the following is NOT a benefit of cross-training of operators? It is easier to balance the line It is easier to move people around Operator can see the big picture for the process more clearly None. All of the above are benefits of cross-training. The time it takes a product to start at the first operation in a process, to being completely packed and ready for shipping is called: Customer ready time Takt time Lead time Cycle time The kaizen lightening burst is used in value stream mapping to identify projects or kaizen activities that will have to be undertaken to reach the future state from the current state. True False A manufacturing system is called a push system when products are manufactured based on a forecast that has been created using customer demand. Actual Real Estimated Derived Which of the following is NOT a characteristic of a workcell? Teaming through common goals and incentives Created independent of the overall product flow to enhance efficiency Capable of adjusting to fluctuating demands Each worker operates multiple stations All of the above A production system is called a pull system when the is (are) controlled through replacement of what has been consumed. incoming orders from customers outgoing orders to vendors flow of products through the manufacturing process all of the above It is essential to "walk the flow" in creating a value stream map. This means you follow the entire process from beginning to end as if you were an inventory item in the process. True False The problem with mass production is that people are focused on optimizing pieces of the system rather than looking at the entire value stream. True False Question 19 1 / 1 pts How will you define a process owner? A process owner is one who buys parts and spares for the process A process owner processes parts on the process A process owner takes the lead in making the process better over time All of the above are definitions of a process owner Takt time synchronizes rate of production to match rate of . ordering manufacturing sales product movement All of the above are true Which one of the following is NOT included in a value stream map? The flow of raw materials The flow of capital The flow of information All of the above The pacemaker process is: Usually the last operation in the product flow The bottleneck process in a value stream Both of the above None of the above The VSM manager should report to the: Plant manager Production manager Department manager Highest manager in the facility It is always a good idea to begin to create a value stream map by first considering the: Operator Supplier Customer Machine manufacturer A useful concept in identifying waste in motion is work content. Which of the following is the ratio that can be used to define work content? Motion/work Correct Answer work/motion Waiting time + work time Work time + (Motion/work) The correct answer should be work/motion Which of the following are lean principles? Simplification Concurrent engineering Design for environment (DFE) All of the above Which of the following 5 Ss refers to orderliness? Seiri Seition Seiso Seiketsu The chapter listed Canon Corporation’s nine wastes that organizations should seek to eliminate. Which of the following are Canon’s wastes? Green programs Planning Design for environment (DFE) All of the above The chapter listed Canon Corporation’s nine wastes that organizations should seek to eliminate. Which of the following are Canon’s wastes? Operations Startup Equipment All of the above Which of the following are included lean principles? Cleanliness Visibility Cycle timing All of the above In a two machine line, operation time for each item in machine 1 is 10 minutes, Operation time for each item in the second machine is 5 minutes. Time needed to process this three item batch in this two machine line is : Correct Answers 45 A company produces 1200 parts in a 5 days week. They work in one 8.5 hours shift on each day. Assume that the company has 30 minutes paid lunch beak on each day. What wiil be the takt time/product? 0.5 2 4 3 In a production line there are two operations: operation one generates 1% scrap, operation 2 generates 2%, overall scrap rate will be: ( try select the 3% 2% 2.98% 9.7% A company has a demand for 120 items /day. They work two eight hour shifts per day. In each shift they have one 20 minutes coffee break. Their Takt time is: 8 16 7.67 8.6 In a Value Stream two production lines work in sequence to supply one of the sub-assemblies to final assembly to complete production of a product. Lead time for production line 1 is 100 minutes for finishing operations needed on this line, then the subassembly is supplied to next line 2, that takes 110 minutes for complete processing of the sub-assembly on this line, effective lead time for the two production lines up to the assembly : 100 minutes 110 minutes 210 minutes Non of the above answer is correct. The TQM integrated framework presented in the book includes coverage into which of the following business functional areas? Purchasing Accounting Economics All of the aboove Toyota first used the term “Six Sigma”. True False Which of the following are dimensions of quality mentioned in the book? Performance Features Conformance All of the above The customer’s perspective of quality on how well the product compares to what the customer expects from it, is called “fitness for use”. True False A good example of process capability is visual management. True Correct Answer False The answer is false . The term “quality of conformance” represents the ability of a product as designed to satisfy or exceed customer expectations. True False In a two machine line, operation time for each item in machine 1 is 10 minutes, Operation time for each item in the second machine is also 10 minutes. Time needed to process a three item batch in this two machine line following a move one, make one and follow one philosophy will be minutes Correct Answers 40 See here: M1 M2 Total Minutes) Part1 10 min Wait 10 +operation10 20 Part2 10 min Wait 0+operation 10 10 Part3 10 min Wait 0+operation10 10 40 In a Value Stream two production lines work in sequence to supply one of the sub-assemblies to final assembly to complete production of a product. Lead time for production line 1 is 100 minutes for finishing operations needed on this line, then the subassembly is supplied to next line 2, that takes 110 minutes for complete processing of the sub-assembly on this line, effective lead time for the two production lines up to the assembly : 100 minutes 110 minutes 210 minutes Non of the above answer is correct. During creating value stream mapping one of the principle is to: Create as many FIFO lanes as possible Produce as fast as possible Choose the pace maker process None of the above In a two machine line, operation time for each item in machine 1 is 10 minutes, Operation time for each item in the second machine is 5 minutes. Time needed to process a this three item batch in this two machine line is : Correct Answers 45 Which of the following is NOT a key question during creating future state mapping? Where do we have to use supermarket pull systems? What process improvements will be necessary? How efficiently we can schedule production steps in our MRP system? Will we build to shipping or supermarket? A company has a demand for 120 items /day. They work two eight hour shifts per day. In each shift they have one 20 minutes coffee break. Their Takt time is: 8 16 7.67 8.6 Based on following Table compute % VAT for Dept 3: ( select correct up to two decimals for the VAT %) Consider Color matched ones are the VATs( Value added times) , for example: VAT for Dept 2=20, Time in cell DEP2-DEP2: 20 ( which is color matched with the DEPT 2 in the left column and DEPT 2 in the Top Row :20. So 20 is the Value added time or VAT for DEPT 2. DEPT1 DEPT2 DEPT3 DEPT4 DEPT1 20 30 40 10 DEPT2 30 20 0 15 DEPT3 40 20 30 5 DEPT4 10 12 8 10 Total time NVAT VAT Correct Answers 38.46% In Lean approach which of the following is applicable Reduced Lead times Individual develop high skills Performance measurement is by department employees are responsible for departmental function Current VAT for a process 10%, Your value added time is 100 minutes, how much is your current NVAT(non value added time) 1000 500 900 800 If VAT 100, NVAT =150, % VAT will be 33% 40% 66.67% None of the above answer is correct 60,000 parts are needed per year and it is produced four times per year at the rate of 20,000 per batch. True False Kanban is a visual system for controlling flow of materials. True False Which of the following situations are not suitable for PULL production Long setup time requirements and unreliable production machines Very fast production pace for some operation High defect levels in the process Each of above are limitations of PULL production One of the requirements of PULL production is that the process must have high capability for meeting specifications requirements of the parts in every case True False Select the correct statement: Pull production needs detailed schedules for each operations Pull production depends on the production and transfer of materials decisions from management Pull production eliminates need for schedules at every operation Pull production needs management involvement at every step. Select the right answer from the following statements to fill in the gap: in PULL system , whenever buffer stock drops to a certain number of containers order is placed to procure the items and fill the buffer stock producer gets signal to replenish the stock in the buffer area materials transferred from warehouse through materials requisitions kept at that level to minimize inventory In a PULL system: whenever consumer step/stage needs parts, it takes them from the buffer stock . True False Which of the following role is played by producer in a PULL system keeping the buffer stock replenished producing more when buffer stock drops to some minimum level Correct Answer first and second statements as given above producing according to the schedule received from MRP The correct answer is first and second statements as given above For support and administrative processes, inventory is: The office supplies and other inventory at the operations Correct Answer Time delays that are adding up between operations There is no inventory in between the operations in a business process None of the above applies The correct answer is b: For support and administrative processes, inventory is time delays that are adding up between operations. It is essential to "walk the flow" in creating a process value map. This means you follow the entire process from beginning to end as if you were going through the process. True False A process map is converted into a process value map (PVM) with the inclusion of operation and waiting times between operations. True False In traditional Process environment Managers could allocate work to as many employees as needed True False When analyzing each operation or step in a process, you can: Eliminate the operation Merge it with previous operation Merge it with the next operation Correct Answer All of the above The correct answer is d. When analyzing each operation or step in a process, you can eliminate it or merge it with the previous or the next operation Pareto analysis is included as one of the step in creating lean processes: To eliminate waste To reduce cycle time To identify the vital improvement functions and/or vital waste sources To guide the team in a step by step ways Usually there may be multiple value streams in a process True False In Lean approach which of the following is applicable Reduced Lead times Individual develop high skills Performance measurement is by department employees are responsible for departmental function If the sum of the downtime for equipment repairs is 125 hours and you had a total number of 10 repairs, what is the mean time to repair (MTTR)? 0 15 12.5 500 Which of the following is a formula for measuring availability for equipment repair given in the book? MTTR/(MTBF+MTTR) MTBF/MTTR MTBF/(MTBF+MTTR) MTTR/MTBF Well functioning equipment is the prerequisite for which of the following: providing training to operator customer focused quality improving setup time engineering change to machine Preventive maintenance (PM) is credited in the literature with benefits including which of the following? Improving productivity Comparing productivity and customer requirements To eliminate quality based rejection as a reactive step. What is the reliability that equipment will perform properly under normal operating circumstances if the number of successes with equipment operation is 500 and the number of times the equipment is planned to be operated is 1000 in producing the 500 parts? 0.10 2.00 0.5 None of the above Autonomous maintenance means installing of automatic equipment to automatically conduct maintenance on a machine. True False The preventive maintenance schedule for a TPM implemented shop would be based on calendar time and not machine run time. True False What are the ideal goals that are NOT sought to be achieved through OEE? Equipment operates when needed Equipment runs at the rated speed Equipment produces only good product Equipment has zero unplanned downtime and zero setup time None. All of the above are ideal goals to be achieved through OEE. Predictive maintenance is done by the operator with support from the maintenance department. True False Which of the following is NOT a responsibility of an operator in a TPM environment? Measure and prevent equipment deterioration Report equipment abnormalities Participate in equipment improvement None. All of the ones are responsibilies of an operator in a TPM environment. The health of manufacturing equipment is a key factor in maintaining high quality and productivity in a manufacturing company. True False Question 12 1 / 1 pts 50% of premature rotating machinery failure is due to misalignment of members. True False Which of the following is NOT planned downtime? Preventive maintenance Correct Answer Breakdown maintenance Routine maintenance Overhauling of a machine Answer is B. Breakdown maintenance is not planned downtime. Doing which of the following will NOT increase the overall equipment effectiveness (OEE) for a machine? Increasing availability of the machine through reduced planned downtimes Increasing setup times Eliminating defects All of the above If the availability (A) of a machine was 90%, the performance (P) was 95%, and the quality (Q) was 99%, what would the OEE be for the machine? 94.7% 284 84.6% Cannot be determined Infrared thermography is used for all EXCEPT: Electrical distribution systems Alignment of machine slides Molds and dies Heat exchangers For one major accident, 300 near misses have been ignored. True False To improve OEE, which of the following is NOT suitable? Increase availability of machine Eliminate setup times Eliminate defects Increase unplanned breakdown maintenance time None. All of the ones shown above increase OEE. Equipment trials after installation of equipment at your shop should be done by the machine manufacturer and not the company's start-up team. True False Match the effects with the correct causes when doing oil analysis: Oil has darkened from its original color Overheating of some parts and oxidation of the oil Oil has turned black Contamination with wear particles due to friction Oil is cloudy Contamination with water or some other liquid Which one of the following is NOT a good kaizen rule to include when performing a kaizen blitz event. Never leave in silent disagreement Seek the knowledge of one person rather than the wisdom of ten people Keep an open mind Keep a positive attitude and have fun Think creativity before using capital An organization should pursue continuous improvement for its product and proceess To earn more money to address changing customer requirements To satisfy share holders To improve organizational image Kaizen process can be used to improve almost any process True False A Kaizen team Facilitator should not: Act as a coach for the team Provide necessary knowledge to the team. Take the role of a leader Emphasize team success. Which one does not fit to be a Kaizen goal Goal must be measurable Goal must be tied to meaingful performance Creating a rough basis for future discussion Keep lean manufacturing principles in focus Change in the business environment is the main reason for pursuing kaizen to adapt to change, such change comes from which of the following reasons: Natural Calamity or other disastrous situation Change in the business ownnership competitors launching of new product Change in the union management relation It is essential for the facilitator to be detail oriented and take on the role of the team leader when circumstances dictate. True False The correct answer is b. The statement is false Kaizen events may be mentioned as Learning experience True False People should be trained to not ask dumb questions during a kaizen event True False When should you consider company expectations in conducting Kaizen event? After completion of the job or Kaizen project During preplanning the event During establishing mission of the team When you establish code of conduct for the team Which of the following is not essential for good team leadership? Take the initiative Assist in change Establish strict discipline Project energy Which of the following event does not qualify to be Kaizen event: Improving setup time from one hour thirty minutes to one hour Correct Answer Invention of an electronic device improved the process productivity by 25% Improving market growth by 2% over the last two years. Process capability improved to 1.2 from 1.0 Statement 2 is not a Kaizen event Select the appropriate answer : Kaizen can only be used in manufacturing setting Kaizen process can be used to improve almost any process Kaizen should not be used to improve a process that involves multi- department Kaizen process is not suitable for research projects Facilitator provides to solve a problem, select the right word for the blank Solution tips key guidance Which would you say best describes kaizen? Giant step forward Continuous improvement Perfection All of the above Which of the following is done by facilitator? Collects results for each activity Keeps upto date record for team activities Sets due date for a job Follows up such that the team work continues up to completion of the job The statement, " Select a job that will improve the bottleneck situation in some area of a business " is always applicable while selecting a Kaizen event target: " True False Which of the following should not be a Kaizen event Target: The event has high probability of success The event will improve employee morale Correct Answer The identified problem seems to be difficult One of the quality improvement step identified during group discussion. A problem that is difficult to solve should not be a Kaizen target Say demand=50 units/hour, capacity of a kanban or container =35, you need safety factor 10%, lead time for production of the parts in a machine is 4 hours, how many kanbans are needed ( make it a rounded next higher number). 7 9 8 4 A factory keeps buffer stock between two work stations, time to move the container of parts between the machines is negligible, demand for parts D=22 units/hour, production lead time (LT) is 2 hours, the factory keeps 20% safety stock for the parts, container size = 6 parts, Compute rounded number of number of kanbans(K) to be maintained in between two stations. 6 9 10 7 eople may not be needed in the 5S implementation team includes: A quality assurance expert Facilitator Manager of the area Employee from the work area Red tag does not provide reasons for Red tagging True False 5S phase that is focused on safety is sort set in order shine Stnadarize In a 5S project when project target and details are set, you do not need: to measure your progresss to gather informtion identify project charter Workplace scan 5S cannot reduce cost True False Red tag is used set in order sort Standarize Sustain Questions/criteria/considerations for red tagging do not include: Last time use of the item Is the item expensive? Use frequency of the item Does the item has a function in the area under consideration? Temporary location indicators are similar to Red Tagging True False Which of the following is not a a function of Red tag: Providing alarm on entering an area Identifying unneeded items identifying misplaced items Showing signs to move an item to a holding area Red tag establishes rules for the misplaced and unneeded items True False Red tagging is a visible way for identifying items that are in the wrong place True False Which of the following is not a fundamental strength of 5S Correct Answer It improves revenue It improves quality It improves safety it improves cost Revenue improvement is not a fundamental of 5S Which of the following statement is not correct for the location of Red tag holding area Should be outside the plant building to avoid barrier to flow of items Should be at the central area of the plant should be in a highly visible area Should be clearly labeled with rules Information that are to be collected prior to starting of 5S project includes: Company declared reward program for successful completeion Workplace scan, Photos of the as is location before implementation Recording of locations and subject At which 5S phase worn out pipes, damaged hoses, faulty valves, and defective wires are replaced Staandarize sort Shine Set in order Steps for controlling contamination is implemented in : sort set in order shine standarize Which of the following 5 Ss refers to orderliness? Seiri Seition Seiso Seiketsu A useful concept in identifying waste in motion is work content. Which of the following is the ratio that can be used to define work content? Motion/work work/motion Waiting time + work time Work time + (Motion/work) Which of the following are lean principles? Correct Answer Simplification Concurrent engineering Design for environment (DFE) All of the above Simplification is included in Lean principles Toyota’s seven wastes that organizations should seek to eliminate include which of the following wastes? Product defects Transportation Inventory Correct Answer All of the above None of the above Visual management can be a good means to control or punish people. True False Visual factory is not set up with : signs guides labels color coded marking What is meant by the hidden workplace? Employees tend to hide tools Vital process and performance information is hidden and not available easily to all of the employees Employees are reluctant to share information with others Employees hide work from others Visual workplace does not put end to: searching waiting contaminating delays A Visual Workplace can eliminate the need for 80% of daily or weekly status meetings. True False How visual workplace ensures precision? By including visual measuring device to ensure precision setting Providing standard work instruction, specifications , last achieved level Visually instructing skill requirements and skillful operation Including computerized setting Visual work place limits information dissemination by managers True False Which of the following is a visual control? Construction site alert sign Mileage limit Trans fat label on food package Substances with marks Flammable Visual device does not include: visual indicator Visual signal visual control visual basic Usually a term that can NOT be associated with a visual workplace is that it is: Self-explaining Self-regulating Self-ordering Self-starting Visual communication can clearly provide work instructions. True False Visual charts should be directed toward the individuals and not teams in creating a visual workplace. True False Question 13 1 / 1 pts It is essential to change a company's mode of management and organizational performance metrics, before undertaking to institute a visual workplace for communication. True False Monitoring of work order by visual workplace is not ensured The statement is incorrect, monitoring means following up for timely completion The statement is correct. Monitoring gets meaning only when a authorized person checks The statement is correct considering some body needs to note the monitored and updated information The statement is neither correct nor incorrect. The traditional PUSH system is centralized but PULL system decentralized. The reason being in PULL production: ( Select the most correct answer) The shop floor supervisors and work teams concentrate on individual work. The shop floor supervisors and work teams perform much of the detailed capacity planning. The shop floor supervisors and work teams perform scheduling and work control Answers in 2 and 3 Visual management pinpoints: Areas in the shop floor having problems Flaws in the standard working Procedures Political vulnerability of the of the Ste. None of the above are correct. Difference in the objective of data collection for traditional and Lean Companies : Purpose of Data in Traditional companies are to impress managers but in Lean Data is used by front line workers for scheduling and controling Traditional companies collect plant data for Centralized PPC system but in Lean data is collected for Front line workers for their Scheduling and controlling of work None of the above are correct. Data collection and use purpose are same for any system Copy of The traditional PUSH system is centralized but PULL system decentralized. The reason being in PULL production: ( Select the most correct answer) The shop floor supervisors and work teams concentrate on individual work. The shop floor supervisors and work teams perform much of the detailed capacity planning. The shop floor supervisors and work teams perform scheduling and work control Answers in 2 and 3 Many PULL production companies have direct Kanban Link to their suppliers. True False In a Visual management Factory Information displayed or posted include which of the following: Weather Condition/forecast News on football Measures of quality Suspension information of an employee Quiz Score: 20 out of 20 Smaller the set up time, the smaller the feasible batch size True False Setup time is the time elapsed between producing the last unit of one batch and the first unit of next batch Correct Answers good In a Lean approach Setup is done by skilled operators such that adjustment time is reduced by the good setup person True False Setup reduction was not given much importance in the past, the reason being: Setup time did not increase cost Managers used to produce big batch to absorb cost for set up time There was no competition None of the above Select the correctly matched setup related work Find out next operation Internal task Remove the old tool from the tool holder External task Check the part drawing to decide sequence of operations External task Get new materials for the next job Internal task Before SMED improvement techniques were adopted for setup reduction, highest % of setup time used to be spent for: (select the right answer from the following) Preparation, checking, storing, and moving materials Removing and mounting parts and tools Machine measurements, settings and calibration Trial runs and adjustments To achieve " abolish the setup ", the 4th step of SMED procedure, you should complete the first three steps always. True False SMED procedure is used to reduce changeover time of dies only True False Say you produce five different products in a machine and the machine needs changeover time 2 hours for changing from one product to next. To justify changeover time if you run each product for one day, how much time will elapse between production runs of each product? Correct Answers 5 The question is self explanatory.You produce 5 products in one cycle and produce one product one day , so you need 5 days for one cycle, now go for next cycle , and repeat, interval between production of a product is 5 days. In which changeover step we try to transform internal setup works/times to external setup work/time Documentation Analyze Standardize Implement Which of the following can give you scope to abolish your setup time? You have one left hand and one right hand steel bracket and you planned to produce both in one forging die and one stroke of the Forging press. You divide setup operation into internal and external tasks and perform the tasks accordingly You train your operator in changeover works You modify the machine for quicker adjustment for setting up If you dedicate one machine for one type of product, you do not need any changeover or setup True False Which of the following may not be considered as setup reduction technique? Using checklist to perform each setup step with standard procedure Using quick change fasteners or attachments to reduce setup time Using robots to perform changeover Using specially designed shims and guides to reduce adjustments Your changeover time from one product to next for a machine is 2 hours and you run each of your product for 1.5 days to absorb the changeover cost. Now your changeover time is 10 minutes, what should be your production run time for each product now? Consider each day of 8 hours. Correct Answers 1 To absorb cost of change you needed to 1.5*8=12 hours product. Now changeover time is 10minutes/(2*60 minutes) th =1/12th of previous changeover time , so you should run only 1/12 th time or 12/12= 1 hours. The smaller the setup time, the lower is the WIP inventory True False In which step we video tape the Changeover operation Documentation Analyse Implement Standardize It is a multiple answer question. Benefits of reduced setup time includes: It saves managerial times It improves quality of product Correct! It reduces Process Variability It makes product attractive Reduction of setup time for only one of the machines in process : Can provide all the setup reduction benefits It can not provide any benefit until setup times for all the machines in a process are taken careoff. It will provide limited benefit that is contributed on set up reduction of one machine So reduction of Setup reduction project may be avoided How does setup time reduction improves flexiblity? By Freeing time for highly skilled Setup workers By increase in machine capacity with the addition of Freed up setup time By buying extra capcity None of the above answers are correct In a setup operation for a job there are 5 steps and together they need 90 minutes. Since each of these operations are to be performed by keeping the machine in stopped condition, these 5 operations are: External setup operation Correct Answer Internal setup operations They can be mixed , description of the operations are needed to decide the types All of the above answers ae incorrect You keep the machine stopped only for the internal setup operation, Answer #2 is correct Producing less than requirement or under-production is not as bad as the over production True False Which of the following is not a characteristic of right sized equipment? Easily maintainable Easy to operate Requires very low amount of time to produce a product Can produce highest quality outputs Right-sized equipment allows us to balance operations so that we can have a constant flow of products in a lean manufacturing environment. True False Lean Equipment can contribute in reducing transportation loss by which of the following statement Right sized equipment is integrated with transportation arrangement Right sized equipment produces for market It produces what are needed Right sized equipment does not have product at input or output side You are selecting material handling equipments(MHE) for a factory that has two production lines. Line 1 has 500 Kg product bin and line 2 has 100 Kg product bin to be trasferred by the MHE to the finished goods store after every 30 mins interval. Please select the right sized equipment from the following offers based on the information given: Offer for a Fork lift of 1000 Kg capacity , will cost $ 35000. It will need 3 mins for each transfer Offer for two Hydraulic Pallet Truck( manually pulled/pushed type); each of 750 Kg capacity and will cost $2000. The pallet truck will will need 6 minutes for each transfer Offer for a comaptible conveyor system for continuous transfer, needs $50,000 investment. Which of the following statement describes right sized equipment ? Very high capacity and high quality production machine Adjustable capacity reliable machine to take care of the market growth potential for some years Multi task sophisticated machines Simple single task machines with fixed required capacity with 50% reliabiliy Which of the following is NOT a cause for overproduction? Incentive or reward for higher productivity Production to keep safety stock to take care of the unreliable shipment by suppliers Production to take care of consumption of the next process during set up time of the machine Piling up of inventory due to non-delivery to the customer on a cyclone day Which of the following is NOT a concept of right-sized equipment in a lean environment? Build equipment to perform only the value-added steps in a product Break down multi-task machines to single operation machines Large machines sitting on immovable foundations are replaced by small, adaptable machinery. None. All of the above are characteristics of right-sized equipment. Overproduction in a processing step creates non-balanced production scheduling problem. True False A lean equipment should : Have capacity to fulfill requirement of the next process Ensure maximum machine utilization Flexible to accomodate design and volume change up to an expected level Have the characteristics described in a, b, and c Correct Answer Have characteristics described in a and c You need to select an offer to buy a machine based on your idea for right sized or lean equipment submitted by four suppliers Offer 1: have required capacity to fulfill daily market demand in two shifts, needs one operator in each shift to run Offer 2: have capacity to fulfill daily market demand in 1.5 shifts of operation, needs 2 operator in each shift to run Offer 3: Have capacity to fulfill daily market demand in one shift operation, 3 operators needed Offer 4: An automatic machine that can fulfill daily market demand with 3 hours of operation with only one hour and one operator involvement. Select the the statement that describes the characteristics of a lean equipment A machine takes short changeover times for changing to different products Latest technology higly automated machine with very high production capacity A fork lift of 8 ton capacity is used in the factory to transport 200 Kg loads inside the factory To fulfill the daily market requirement a machine is needed to run 8 hours for processing the jobs allocated to it, but it takes one hour warming time in the morning before starting the production. A Process Layout follows --------- and production flow path Smooth , single directional Zigzag and long Traditional and u-type None of the above are correct One of the advantages of cellular layout : It reduces cycle time It is flexible for quality and Design Changes Improves quality Creates on line communication with customer Answers 1,2 and 3 are advantages of cellular layout A Lean Lay out Adds latest Technology Materials handing equipment Facilitates establishing environmental sustainability Avoids unnecessary motion/handling Plans avoiding long distance travel to reduce energy consumption and Cost of movement For becoming a Lean layout : Flow must follow a value Stream Map path Flow must be progressive from receiving to shipping without and stoppages Flow path should not have backflows All of the above are correct Lean Layout influences waste reduction by which of the following: Creating single piece product flow Reducing cycle time by including smooth flow of product with no Zig -Zag movement Exposing pile of inventory to mangement All of the above steps influences waste reduction A cellular Layout is : an example of process layout An example of product layout not as efficient as a product layout Is not unidirectional and as such not efficient Lean layout favors : Product layout Process Layout None of the above Both Product and process layout Lean Layout is flexible for the following feature: Lean favors including light movable machines that helps to obtain Flexible layout Lean favors including of cellular manufacturing arrangement By providing cross training to the operators By keeping more than one machine for each equipment Answers 1 and 2 Question 1 1 / 1 pts Bar Coding may be considered a Poke Yoke device that facilitates built-in checks in operations True False Which of the following statement is most relevant to Poke Yoke Poke Yoke system only detects error Poke Yoke may be described as error cause removal Main reason for integrating Poke Yoke into a process is to ensure safety to the operator Poke Yoke may be defined as an inspection process Poke yoke ensures perfect product quality by 100% inspection True False Sensors are used for : Control based Poke Yoke steps Alarm based Poke Yoke steps Sensors can be used for control as well as Alarm based Poke yoke Sensor are not poke yoke device Counting based Poke Yoke are control system True False Which of the following is NOT a Poke-Yoke device? Heijunka board Guide pins Limit switches Checklist Which of the following is NOT a characteristic of Poke-Yoke: Immediate feedback if a non-conforming condition has arisen. Correct Answer Statistical quality control is conducted on the part being produced 100% inspection happens as a result of the Poke-Yoke device The system stops if a non-conforming situation has arisen and notifies the operator Answer is B. In Poke-Yoke, statistical quality control cannot be said to be conducted on a part being produced since the very nature of a Poke-Yoke device allows 100% inspection. Classical inspection detects defects to maintain the quality of parts. The idea in Zero Quality Control is to prevent defects from occurring in the first place. True False Poke Yoke system is used for Controlling errors from happening Detecting errors Alarming the operator of an error to fix the problem the first and third answers listed above the first and second answers listed above Poke Yoke eliminates or reduces waste: By various sensors By guide pins and checklists By eliminating quality failure scrap By eliminating set up time Select the statement that does not describe control system based Poke yoke Shuts down the process Keeps the defective parts aside Provides a beep sound when schedule comes for next step. Does not allow operator to progress when sequence is not followed The farther a defect is detected from the point of origin, the lower the cost of fixing it. True False When do we need Poke Yoke? When scrap rate is high in a production process When a company is facing heavy warranty claims When process failure results product defects When company decides to implement Poke Yoke Poke Yoke was developed by: Deamming Feigenbaum Shigeo Shingo Phillip Crossby When do we need Poke Yoke? When company is loosing market due to inferior quality When exception in operator performance result in product defects Company is under pressure to ensure product quality When customer complaint s are continuously increasing Poke-Yoke comes from the thought that people are fallible, and mistakes made by them should be tolerated. True Correct Answer False Statement is false. Poke-Yoke comes from the thought that people are fallible, and hence we should provide them with the means to minimize/eliminate opportunities to make mistakes. Poke Yoke ideas generate from Front line workers: These ideas include: How they can eliminate their own mistakes To analyze and work out details where technology is involved. Finally based on the idea they team up with team leaders and supervisors to solve the problem All the above points true according to your text book 80% of defects are management controllable. The reason being : ( select the most correct answer) workers do not have adequate knowledge Workers do not have adequate process to do quality work These are arguments but workers should also take responsibility Correct answer should be answers in 1and 2 Correct answer should be answers in 1, 2 and 3 Jidoka according to your text : Refers to automatic control of defects It is automatic shutdown of a process when process is generating defects The concept is also called autonomation. All of the above points are correct Inspection process itself is not error free. Steps taken to reduce inadvertent inspection error include: ( select most correct answer) Providing training to the inspector Punishing inspector if error is found after training Checking measuring equipment and calibration Correct Answer Answer in 1 and 3 are correct Answer 4 is the most correct choice Select the correct answer for Bottleneck machine and current capacity of the line in the attached figure TOC MC1, 5 MC2,15 Assembly ,40 MC4, 10 The theory of constraints approach measures financial performance using: Standard cost Throughput accounting First-in, first-out accounting All of the above. In the principle of TOC , sub-ordinate everything to the constraint means: Run all non-constraint resources based on the requirement of constraint resources Run non-constraint resources since you can not run constraint resources Non-constraint resources are not needed to be controlled, take care of constraint resource only Constraint resource is the highest production machine According to TOC a constraint can be : The company policy to achieve equipment utilization The Bottleneck machine A company norm for utilizing standard lot size Correct Answer all of the above The correct answer is d. all of the above may be a constraint Drum rate in TOC is the: Constraint resource rate or CR production rate It is the rate, which a company declares in its forecast It is the production rate of each machine It is the customers requirements According to TOC, to manage a business well: We need to manage the productivity of each machine We need to manage our total asset utilization well We need to manage the constraint None of the above The main idea behind the theory of constraints is that all organizations exist to achieve a goal, and in most cases the goal is to make money. True False The Rope as mentioned in TOC is used for time frame release of material or information to the non- constraint resources. The rope is used to mention the weakest link of chain Ties constraint resources with other non-constraint resources does the functions mentioed in a. and c. A constraint may be an operation step that has limited capacity compared to what is needed to satisfy the market need. True False Lean in offices will result lowering of manpower by making office employees efficient True Correct Answer False The answer is false Application of lean in offices is difficult because of unwillingness of office employees to any change True False Non Value added work but the work is necessity include: The work/task does not add value but for completing the product or you need that task This is conceptual only. What ever is decided by management that becomes necessary Since these are non value added work, they should be eliminated . The definition is not clear Pure waste may be understood as: ( select the most correct answer) Tasks that does not add value but consume resouces These are in fact steps that do not add value but consume resources and they are possible to to be eliminated Since customer will not agree to pay such non value added task, they are wastes Correct Answer All of the above are correct. Answer 4 is the most correct answer Some tasks that does not add value and customer does not want them but consume resources , they are waste and should be eliminated True False So non-value added tasks are of two types, they are: Pure waste and Non Value added but management thinks they should not be termed as pure waste Pure waste and Non Value added work but necessary for completing processing of the product Pure waste and partially waste, because some application are there for some wastes The above answers are incorrect A lean office management can effect all levels of organization by: Reduction of error with close monitoring Higher productivity Reducing cycle time for each office work Correct Answer Reducing office work quality problems by standard work Answer4 is the correct choice because standard work will reduce personal work error or individual employees An office System Value Stream can not be balanced because of inherent variability of the office work True False What scheduling system is used in theory of constraints to schedule production? Drum-buffer-rope The Rope as mentioned in TOC does the functions mentioed in a. and c. The way to calculate throughput in the theory of constraints is to subtract the production cost of product from its price . False Manufacturing strategy considers which one of the following as one of the important factor: Skill sets of the production managers Cost The following may be considered as the stage(s) for supply chain integration: statements in b and c Which of the following may be considered as one of the driving forces for changing landscape of the businesses: Deregulation Which of the following is not a goal for supply chain or lean supply chain Use latest technology plant In a Value Stream Mapping we need to consider We need to consider both a) and b) Which of the following is NOT a key question during creating future state mapping? How efficiently we can schedule production steps in our MRP system? In the current state Value Stream Mapping process which of the following information is NOT needed: Cost of machine Which of the following statement is true for the pacemaker process: Statements a and c are true for pacemaker process Which of the following is NOT a characteristic of a workcell? Created independent of the overall product flow to enhance efficiency How will you define a process owner? A process owner takes the lead in making the process better over time. In a stepped diagram created to calculate the %VAT or the VAT/NVAT ratio in value stream mapping, the lower time line is the: The actual processing time which is considered the value added time from the customer's viewpoint. Which of the following is NOT a benefit of cross-training of operators? None. All of the above are benefits of cross-training. To derive the cycle time for a process: Divide the processing time for the pieces processed on the machine by the number of pieces processed in one cycle The Value Stream Manager is accountable for: All of the above A value-added activity can be described as: Any activity that increases the function of the product or service Any activity that the customer is willing to pay for Both of the above It is essential to "walk the flow" in creating a value stream map. This means you follow the entire process from beginning to end as if you were an inventory item in the process. True The kaizen lightening burst is used in value stream mapping to identify projects or kaizen activities that will have to be undertaken to reach the future state from the current state. True Question 31 1 / 1 pts If the cycle time is more than the Takt time: You will not be able to satisfy all customers More operators and equipment will be needed The efficiency of the operation will have to be increased All of the above