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A) Variation in quality
A) Finite loading
B) Infinite loading
C) Interoperation sequencing
D) Dispatch lists
I. Routings
A) I and II
B) I and III
C) II and III
I. Lot sizes
II. Lead times
III. Queue sizes
A) I and II
B) I and III
C) II and III
A) Start with the current date and calculate the order due date by the time of each operation
C) Starting with the order due date, calculate the start date of the order by going back through each operation
7-When orders are assigned to the factory without any restrictions on capacity, this is known as:
B) overloaded.
C) unsmoothed load.
8- own as the:
A) Standard rate.
B) Cycle time.
C) Capacity rate.
D) Setup time
9-
complete the job? (Round to the nearest whole day)
Machine = 2
Number of operations = 2
A) 6
B) 7
C) 8
D) 9
10- Which of the following best describes the forward scheduling technique?
I. Begins with a known start date and calculates a completion date for an order
II. Dates generated are earliest start dates for each operation
A) I and II
B) I and III
C) II and III
A) I and II
B) I and III
C) II and III
13- Which of the following statements are true regarding lead time?
I.
II.
III.
A)
I and II
B)
I and III
C)
II and III
D)
A) I and II
B) I and III
C) II and III
15- In order to determine the operation duration, which of the following would be included?
I. Setup time
II. Wait time
III. Run time
A) I and II
B) I and III
C) II and III
A) I and II
B) I and III
C) II and III
C) equal to 1.0.
18- Which of the following will be true if the cumulative lead time of a product is longer than the MPS planning horizon?
C) Order point can be used for the longest lead time items without affecting priorities.
D) There is no impact.
A) I and II
B) I and III
C) II and III
20-
21- Which of the following are requirements for a shop order release?
I. Parts availability
II. Order due date
III. Tooling availability
A) I and II
B) I and III
C) II and III
22-A company makes long runs of parts in a sequence of work centers. Because of this, they start the second operation
before the job is completed at the first operation. This method of scheduling is called:
A) Lead-time offsetting
B) Overlapped scheduling
C) Capacity overlapping
C) A schedule in which products and lot sizes vary so every model is made every day
26- In the electronics manufacturing industry, there is often a process step called bake at the end of the production process.
The process steps ahead of the bake step are generally completed faster than the bake step. This bake step is known as a:
A) Clogging operation.
B) backflush operation.
C) Gating operation.
D) Constraint.
27- In process industries, such as in an oil refinery, the primary execution and control concern is:
A) Linearity.
C) input/output control.
D) Setup times.
28- Producon or der 650 is for 500 of par t 3009. From the roung fil e, it is det er mi ned that the set up m
e i s 3.0 hour s and
the run me is .25 hour s per pi ece. W
h at is the requi red capaci ty for thi s par t?
A) 120 hours
B) 125 hours
C) 128 hours
D) 132 hours
29- An order for 200 of a product is processed on work centers 101 and 102. The setup me on wo r k cent er 101 is 60
each. The wait me bet we en each oper aon i s 3 hour s and t h e move me bet we en 101 and 102 is 30 m i nut es . The wa i t m
e
ae r wo r k cent er 102 is 4 hour s wi th a m
o ve m
e t os torage of 20 min ut es. W
ha t i s the t otal m
an uf act uri ng l ead me f or t he
order?
A) 28.5 hours
B) 29.3 hours
C) 36.3 hours
D) 39.4 hours
30- Which of the following best describes the term "production activity control"?
C) Procurement activity
B) I and III
C) II and III
A) I and II
B) I and III
C) II and III
33- Preventive maintenance is important in all companies, but is usually the smallest portion of the maintenance budget. For
a lean manufacturing environment, preventive maintenance is critical for which of the following reasons?
III. It extends the useful life of equipment, thereby delaying investment in new equipment
A) I and II
B) I and III
C) II and III
34- A reliable JIT system will not only simplify operations but will also simplify transactional activity in which of the following
areas?
I. Purchasing
II. Shop floor tracking
III. Quality control
A) I and II
B) I and III
C) II and III
Based on the above information, what is the takt time of the line?
A) .6 minutes
B) 1 minute
C) 1.67 minutes
D) 10 minutes
36- In a plant with a smooth flow of products, which of the following scheduling methods works best?
C) Visual/Kanban system
D) Input/output method
37- Many times, companies will implement kanban replenishment and believe they can eliminate all other systems. However,
kanban is not a replacement for:
A) priority scheduling.
B) planning.
C) input/output control.
38- When a kanban size has been established, for example 150 units, inventory can be reduced throughout the process by
constraint. At the point a constraint is detected, a continuous improvement project can be undertaken to eliminate the
constraint so lot sizes can be reduced further. In this example of continuous lot size (kanban) reduction, a critical part of this
process would be which of the following?
A) Cost reductions
B) Flow improvements
C) Setup reductions
D) Accounting standards
39-In a lean manufacturing environment using kanban methodology, many benefits are generated. Which of the following
would NOT be a benefit accruing from the use of kanban?
40-In a "pull" system environment, the final assembly work center is the driving force for the upstream production. In other
words, the final assembly work center "pulls" the remaining production through the rest of the work centers. The reason for
this is which of the following?
D) The dispatch list usually does not list the final assembly work center.
41- A manufacturing process which produces families of parts within a single line or grouping of machines where the machine
operators work only in the line or grouping is called:
A) group machining.
B) repetitive manufacturing.
C) cellular manufacturing.
D) process manufacturing.
44- All of the following are true regarding a daily dispatch list EXCEPT:
I. Operation sheets
II. Pick lists
III. Move tickets
A) I and II
B) I and III
C) II and III
C) the plan for completing a job and the progress versus the plan.
47- A job is due 7 work days from today with 7 hours per day available to work on the job. The amount of work left to
complete the job requires 18 hours. Using the slack me rul e, wh at is the priority on this job?
A) 67
B) 49
C) 31
D) 18
48- The best process for automation is to simplify the work, then automate. When a company does automate with robotics,
it is usually:
50- In the Kanban system, lead time reduction is the responsibility of:
A) Supervisors
B) Materials personnel
D) Everyone
51-Which of the following time frames are usually associated with subcontracting?
I. Short-Range
II. Medium-Range
III. Long-Range
A) I and II
B) I and III
C) II and III
52- If a work center is becoming a bottleneck and throughput time is getting longer, which of the following could be a
solution?
A) I and II
B) I and III
C) II and III
Queson 53, 54,55& 56 Based on Given the following information on a work center:
53-The weekly available capacity at the above work center is: (Rounded to the nearest whole standard hour.)
A) 50
B) 55
C) 58
D) 60
54- If the weekly load on the work center is 72 hours, the work center is:
A) Overloaded
B) Underloaded
C) In balance
55- If the hours worked were expanded to a 12 hour shi, wh at wo ul d the avai labl e capaci ty be? (Rounded to t he nearest
standard hour.)
A) 60
B) 69
C) 82
D) 96
56- If the work week was expanded to 5 days of 10 hour shis , wh at wo ul d the avai labl e capaci ty be? (Rounded to the
nearest standard hour.)
A) 60
B) 72
C) 84
D) 96
I. Maintenance
II. Setup
III. Training
A) I and II
B) I and III
C) II and III
58- When a set-up procedure occurs while a machine is not operating, it is called:
B) interoperation time.
D) gapped time.
59 -Which of the following statements are true regarding Just-in-Time production?
A) I and II
B) I and III
C) II and III
60- The phrase "one less at a time" refers to which of the following?
61- In a job shop environment, it may not be possible to convert all areas to a "flow" shop. Wherever possible the "flow" can
be accomplished by:
A) I and III
62- All of the following are part of starting a Just-in-Time implementation EXCEPT:
63- The process of shutting down a production line or machine upon identification of a defect is:
A) down time.
B) a capacity constraint.
C) simplification.
D) autorotation.
64- An andon is a:
D) successive fixture.
65- Which of the following would be considered waste in the JIT environment?
I. Purchase orders
II. Factory orders
III. Receiving documents
IV. Material requisitions
A) I and II
B) II and IV
C) I and IV
66- Which of the following would best describe the term poka-yoke?
67- The concept of deducting component inventory when finished goods are received into stock is commonly referred to as:
A) floor deduction.
B) allocation.
C) material issues.
D) backflushing.
68-There are 4 categories of quality costs. They are prevention, internal failure, appraisal, and external failure. Which of the
following would NOT be considered an appraisal cost?
A) Inspection personnel
D) Gauge calibration
Period 1 2 3 4 5
PLANNED INPUT 150 150 150 150 150
ACTUAL INPUT 150 145 130
CUMULATIVE DEVIATION 0 -5 -25
Period 1 2 3 4 5
PLANNED OUTPUT 180 180 180 180 150
ACTUAL OUTPUT 185 140 160
CUMULATIVE DEVIATION 5 -35 -55
69- Based on the input/output control chart above, the backlog was reduced by how many hours by Period 3?
A) 30 hours
B) 60 hours
C) 80 hours
D) No reductions
70- Based on the input/output control chart above, what should the input be in Period 4 in order to reduce the backlog?
A) 130
B) 150
C) 160
A) zero defects.
B) conformance to requirements.
72- The term, "empower", can best be defined by which of the following?
I. Flowcharts
II. Scatter diagrams
III. GANTT chart
A) I
B) I and II
C) I and III
74-When a quality problem surfaces within a process, the problem can be identified and analyzed using a cause and effect
diagram. This cause and effect analysis is usually made using a:
A) fishbone diagram.
B) SPC chart.
D) Pareto analysis.
75-In order to certify a supplier, a customer will send an audit team to the supplier site to conduct a quality audit on the
supplier. While the audit team members may vary from company to company, which of the following functions would not be
included in the customer audit team?
A) Buyer
B) Quality engineer
C) Marketing person
D) Materials manager