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MQM 227 – Operations Management | 100 Test Questions on Lean, Quality Costs, 5S, Process Control & Inventory | Illinois State University

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This document presents 100 verified questions and answers from Test 1 of MQM 227 – Operations Management at Illinois State University. The content is centered on Lean principles, quality management frameworks, and foundational operations strategies. Students are tested across a diverse set of topics including the Toyota Production System (TPS), 5S methodology (Seiri, Seiton, Seiso, Seiketsu, Shitsuke), and the seven forms of waste. Detailed assessments also cover the differences between push and pull systems, Kanban implementation, SMED, and setup time reduction strategies. Significant attention is given to quality cost classification (prevention, appraisal, internal and external failures), quality pioneers like Deming, Feigenbaum, and Juran, as well as tools like control charts, P-charts, value stream mapping, and process capability metrics. Additional content evaluates inventory management, capacity vs. inventory distinctions, supplier relationships, and the strategic role of cross-training in lean systems. This is an ideal resource for students in operations management, lean systems, quality engineering, industrial engineering, and logistics. It strengthens understanding of operational efficiency, total quality systems, continuous improvement practices, and value delivery in both manufacturing and service environments. Keywords: operations management, MQM 227, lean systems, quality cost, TPS, 5S, control charts, P-charts, process control, Kanban, SMED, poka-yoke, setup time, value stream, waste reduction, inventory, capacity planning, Deming, Feigenbaum, pull system, push system, Seiri, Seiton

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MQM 227 Test 1 Questions and Answers
100% Correct

Regarding the steps involved in the implementation of a quality cost

program, which statement is incorrect?

A. A pilot program is recommended because it will prove the ability of the

system to produce cost-saving results.

B. It is common to find initial quality cost estimates of more than 20% of

sales (can be reduced to as little as 2-4% of sales)

C. To assure a high probability of success, the unit selected for the pilot

program should be as atypical of the company's operation as possible.

,D. A specific operational area must be exposed in sufficient detail to show

how actual quality costs can be eliminated through analysis and corrective

action. - 🧠 ANSWER ✔✔c


Regarding Deming, which of the following statements is incorrect?

A. In the early 1900s, his father moved his family from Sioux Falls, Iowa to

Cody, Wyoming.

B. In 1924, he received a Ph.D. in physics at Yale (not statistics).

C. In 1947, he was asked to help with the Japanese census during U.S.

occupation.

D. In 1917, Deming began his education at the University of Wyoming

(graduated in 1921).

E. Because of his tremendous help, the Japanese established the Deming

Prize in 1951. - 🧠 ANSWER ✔✔A


Regarding Deming's Deadly Diseases, which of the following statements is

incorrect?

A. Evaluation of employee performance often destroys teamwork, nurtures

rivalry, and builds fear.

B. Running a company on visible figures alone is problematic.

,C. Job-hopping managers never understand the companies that they work

for and are never there long enough to effect long-term changes.

D. An emphasis on short-term profits promotes substantial changes in

production and quality - 🧠 ANSWER ✔✔d


Regarding Deming's Philosophy of Management, which of the following

statements is incorrect?

A. Create consistency of purpose for improvement of product and service.

B. Cease dependence on mass inspection.

C. Remove barriers to pride of workmanship. People are eager to do a

good job and distressed when they can't. Too often, misguided supervisors,

faulty equipment, and defective materials stand in the way.

D. Improve constantly and forever the system of production and service.

E. End the practice of awarding business to the supplier with the lowest

price regardless of quality. - 🧠 ANSWER ✔✔A


Regarding Deming's Philosophy of Management, which of the following

statements is incorrect?




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, A. The job of a supervisor is not to tell people what to do or to punish them

but to lead. Leading consists of helping people do a better job.

B. Institute training. Too often, workers have learned their job from another

worker who was never trained properly or are forced to follow intelligible

instructions.

C. Drive out fear. People are afraid to point out problems for fear they will

be blamed for the problem.

D. Break down barriers between staff areas. Often different departments

are competing with each other or have goals that conflict.

E. Eliminate slogans, exhortations, and targets for the workforce. Slogans

are based on the supposition that employees could do better if they tried. -

🧠 ANSWER ✔✔B


Regarding Feigenbaum's Benchmarks of Total Quality, which of the

following statements is incorrect?

A. Quality is implemented with a total system connected with customers

and suppliers.

B. Quality is a company-wide process.

C. Quality and cost are a difference, not a sum.

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