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WorksheetsMSSC quiz
Total questions: 111
Worksheet time: 56mins
A __________ initiates communication by forming an idea to be shared.
- Barrier
- Receiver
- Sender
- Medium
Communication is a process by which we assign and convey meaning in an attempt to create __________.
- Shared understanding
- Questions
- The method of transmission
- Culture barriers
__________ does NOT help meet the process requirements and product specifications of a manufacturing order.
- Manufacturing the product to meet product specifications
- Overproduction
- Looking for production related problems
- Asking questions when something is unclear
In communication, to avoid making assumptions is a special responsibility of the __________.
- Barrier
- Receiver
- Sender
- Medium
A barrier that interferes with good communication is called __________.
- A message
- Noise
- Feedback
- The medium
Continuous improvement is based on what major goal?
- Daily improvement
- Zero waste
- Structural changes
- Increase improvements
Lean manufacturing is a method of eliminating waste. What is the purpose of eliminating waste?
- Reducing landfill shipments
- Reduce production cost
- Reduce lead time
- Reduce both cost and lead time while increasing quality
A person working downstream on an assembly line is considered a(n) __________.
- External customer
- Internal customer
- Supplier
- Contractor
Making sure that all necessary resources are available at the workstation when required __________.
- Helps to optimize production and make workflow efficient
- Creates a hostile work environment
- Makes the workstation more ergonomic
- Causes undue stress on the employee
Spoken, written, and electronic are three types of __________.
- Email messages
- Communication mediums
- Programming
- Kanban orders
Jidoka builds quality into the manufacturing process. What four steps are used in jidoka?
- Produce, inspect, produce, inspect
- Discover, inspect, produce, inventory
- Discover, produce, inventory, market
- Discover, stop, fix, investigate cause
Lean culture must be deep within the company. What must the company be willing to do?
- Give employees time to observe and study their workspace.
- Give employees breaks to increase creativity.
- Increase wait time between processes.
- Increase production time.
Non-value-added activities are considered waste if they fall into one of the eight categories. Which waste includes poor workplace organization and layout issues?
- Excess motion
- Transportation
- Excess inventory
- Over-processing
The stable operations within products allow the company to add this to its lean manufacturing core?
- JIT
- Standardization
- Jidoka
- Structure
JIT reduces excess inventory, waiting, and transportation by changing the traditional system of inventory to one that focuses on what method of moving inventory?
- Pulling inventory meaning it moves when needed
- Pushing inventory to waiting areas
- Moving inventory into warehouses
- Pulling inventory to reduce back injuries
Effective communication requires everyone to accept __________ in the process.
- Criticism
- Instructions
- Fault
- Responsibility
Standardization is put into place by standardizing work and what other method?
- Increasing production
- 5S process
- Organizing the standards
- Sorting and Straightening
What is the definition of value-added activities?
- Activity that increases the cost or value to the product
- Activity that adds what the customer wants
- Activity that adds processes to production
- Activity that increases the purpose of the product
The best medium to communicate complicated do-it-yourself instructions would be __________.
- Written
- Electronic
- Spoken
- Blog
The best medium to communicate and resolve a conflict would be __________.
- Written
- Electronic
- Spoken
- Blog
The ability to __________ may be a person's most important factor to be successful.
- Be technical
- Read diagrams
- Communicate
- Be tolerant
Brainstorming, organizing, and editing are each a part of the full planning process for __________ a clear message.
- Reading
- Receiving
- Disabling
- Constructing
In which 5S step does the employee look for damaged equipment, worn components, and misplaced objects?
- Sort
- Straighten
- Shine
- Standardize
Top level management must commit to __________ to help sustain 5S success.
- Pay raises
- Promotions
- Team building
- A full staff
__________ is responsible to align the team, establish direction, and to motivate and inspire.
- The quality worker
- Leadership
- The vendor
- A maintenance worker
What is often considered the most difficult step of the 5S process?
- Sort
- Straighten
- Sustain
- Standardize
How does the 5S method aid in the goal of lean manufacturing?
- Reduces the amount of inventory needed to operate the business
- Produces the right amount of the right parts at the right time
- Reduces the waste of excess motion, helps improve morale, and enables other lean methods to be more successful
- Discovers what is wrong with the process, stops the process, fixes the immediate problem, and corrects the root cause
One of the results of Straighten is to __________.
- Free up space
- Arrange items in the order of their use
- Reduce the time to locate tools
- Reduce clutter in the work area
One of the results of Sort is to do what?
- Make sure everything has an assigned storage area
- Store the most often used items closest to their point of use
- Reduce the time to locate tools
- Establish daily cleaning routines
Judging tagged items is part of what 5S step?
- Sort
- Straighten
- Shine
- Standardize
Which 5S step uses labels to clearly identify equipment?
- Sort
- Straighten
- Sustain
- Standardize
When a worker is asked to lift a part or product repeatedly throughout the day, the company should __________.
- Provide a step ladder
- Do nothing, it is not that heavy
- Arrange to move the part to a more comfortable working height
- Always be sure that the person is tall enough to do the task
Which 5S step involves formatting 5S work instructions so that they look and read alike?
- Sort
- Straighten
- Sustain
- Standardize
5S is a lean manufacturing technique that focuses on creating a __________.
- Inventory surplus
- Error free work environment
- Optimized production schedule
- Clean and orderly work area
Which of the following is a key action step of Standardize?
- Free up space
- Arrange items in the order of their use
- Promote best practices
- Reduce clutter in the work area
Inspections completed at each step of a manufacturing process ensure __________.
- An increase in defects
- Quality employees have a job
- Critical parts finish first
- The final material has the needed characteristics
Cause and corrective measures are two things to determine when a component __________.
- Is acceptable
- Fails
- Is missing
- Is modified
Ultrasonic testing __________ to detect a flaw or crack in a part.
- Uses electromagnetic radiation
- Uses high-frequency sound waves
- Creates an image or shadow picture on film
- Paint particles
Large interacting systems are made up of smaller __________ that can fail and cause the system to go down.
- Material characteristics
- Thoughts and ideas
- Components or parts
- Evidence samples
Humidity, temperature, and dust would fall under the __________ branch of the cause and effect diagram.
- Machine
- Material
- Environment
- Method
Which of the following is not a basic step of analyzing a component failure?
- Collect evidence
- Destructive testing
- Develop a Failure Analysis Report
- Create a CAD drawing of the component
Brainstorming in a group is a way to generate as many possible __________ of a problem without deciding if they are good or bad.
- Verdicts
- Causes
- Solutions
- Guilty persons
An assembly drawing shows how the various __________ fit together.
- Inspections
- Production machines
- Parts or components
- Muster areas
Repeatedly applying stress to a part until it weakens represents a __________ test.
- Fatigue strength
- Penetrant
- Ultrasonic
- Hardness
Product characteristics should be classified (critical, major, etc.) to __________.
- Make a meaningful assessment of quality
- Place emphasis on important characteristics essential to operation
- Take action with the responsible individuals
- Perform a quality audit that would be shorter and more meaningful
The primary goal of quality control is to __________ during the manufacture of a part.
- Plan the process
- Address production concerns
- Locate and prevent quality problems
- Maintain the supply
What is the definition of manufacturing resource planning?
- System to manage people within production
- Computer system used to schedule production
- Computer systems used to schedule people for production
- Computer systems used to inventory material and completed products
Prompt communication with a supervisor is necessary when __________.
- The employee notices that he/she is ahead of schedule
- An employee has overlooked a new break policy
- There is a slight delay, even though it will not affect the production schedule
- The production schedule cannot be met
The supervisor should be notified immediately if __________.
- Purchasing is using a new vendor to supply the same material
- Work is on schedule
- The work order is incorrect
- An order is complete
If the correct raw material is not available, the employee should __________.
- Use a similar raw material
- Inform the supervisor
- Call customer service
- Complain to coworkers
__________ should be consistent with a company's strategic goals and objectives and support the overall business plan.
- Inspection reports
- Defect reports
- Manufacturing specifications
- Production plans
What is throughput?
- Process to get materials through the production
- Shipping time throughout the country
- Products produced in a given amount of time
- Products produced within one cycle of production
What is another name for lean production?
- Light production
- Just-in-Time
- Minimal staffed production
- Light process
What is the greatest amount of products a system can produce per day?
- Throughput
- Production capacity
- Production Time
- Takt time
In a production process, the time required to create a finished product is determined by the slowest processing station. The slowest station, often called a __________, therefore limits the maximum rate of production.
- Y factor
- Bottleneck
- Cpk
- Funnel point
What is the rate at which each product must be produced to keep up with demand?
- Throughput
- Lead Time
- Takt time
- Lean time
If capacity is reached, reallocation of equipment and resources is one way to __________ to meet demand.
- Address underperforming employees
- Improve quality through increased inspections
- Lower production costs
- Increase production
Customer lead time is the time between customer order and __________.
- The first manufacturing process
- Product delivery
- Confirmation of order size
- Inspection to ship
What are included on a manufacturing work order?
- Customer address for shipping
- Order and item number
- Takt time and lead time
- Throughput and kanban signal
To identify and eliminate bottlenecks, the __________ required to complete each process must be determined first.
- Extra workers
- Cost
- Time
- Housekeeping
What is the purpose of a kanban system?
- Communicate needs within production
- JIT method of moving products
- Inventory counting system
- Ordering system within shipping
Scheduling overtime is one of the ways to __________ when the production line is already operating at maximum speed.
- Reduce defects
- Improve operator morale
- Increase quality
- Increase production
Customer relationship data is stored in a __________ that can be used to record concerns with specific products.
- Notebook
Thumbdrive
- ERP or database system
- Employee handbook
The daily production schedule is used to allocate the necessary people and equipment to ensure that __________.
- The required production goals are achieved
- No one is just standing around
- Equipment expenditures are justified
- The employees understand that he/she is the boss
Process cycle time is the time required to complete the production of __________ from start to finish.
- Bottlenecks
- A bad part
- One unit of product
- A machine run
What is the unit of measure for Part # FRM-102 described in the following manufacturing work order?
Feet
- Each
- Inches
- Lot
A __________ provides information to the manufacturing department about the product that is to be made and authorizes inventory to be issued to begin the job.
- Process routing sheet
- Process plan
- Manufacturing work order
- Bill of materials
In preparation for repeat orders from a customer, companies __________.
- Store order information and product specifications on file
- Design every product configuration available
- Keep equipment ready to make the product
- Always keep raw stock on hand
Production capacity is a measure of a department's ability to meet __________.
- Customer complaints
- Quality standards
- Supplier demand
- Customer demand
To help track spending and budgeting operating expenses, a __________ form is used to replenish supplies or tools needed for the job.
- Costing
- Tool manifest
- Material requisition
- Routing
It is most important to clearly label any containers of __________ material before shipping.
- Sponges
- Scrap steel
- Plastic pellets
- Flammable or hazardous
Item counts are verified by what?
- Management
- Physical inventory
- Sales figures
- Vendors
Items should be placed in a box that __________.
- Is larger than required so that the box can be used for multiple products
- Has a removable lid
- Is sized to fit so that it does not move excessively after cushioning material is added
- Is attractive to customers
When issued the incorrect, non-conforming, or wrong amount of parts from supply, use a __________ form to correct the issue.
- Kanban stop
- Production stop
- Material requisition
- Discrepant material
The box selected for your product must have a bursting strength of at least 180 lbs per square inch. Which box certificate indicates a box with sufficient strength?
A
B
C
D
The purpose of the __________ is to identify materials loaded onto a truck, the hazards associated with that material, and any special handling instructions to be followed.
- Bill of sale
- Packing slip
- Pallet manifest
- Shipping manifest
Before packaging an item for shipment, the shipping agent should always check for a __________ indicating that the item meets compliance, approved, and is OK to ship.
- Status card
- Inspection label
- Bill of lading
- Statement of approval
What type of shipping uses a truck that may have to make two or more stops to different companies to achieve a full load?
- Part-time (PT)
- Full-truckload (FTL)
- Less-than-truckload (LTL)
- Hot-truckers (HT)
The box certificate shown has an edge crush limit of __________.
- 75 inches
- 65 pounds
- 32 pounds/inch
- 64 inch/pounds
Product damage can be avoided by __________.
- Always lifting with your legs
- Following packaging specifications
- Using a forklift to lift oddly shaped objects
- Stacking finished inventory as high as possible on a pallet
Creating backorders allows a company to save money by __________.
- Waiting until a large order comes in allowing the setup cost to be shared across a large number of items
- Moving these orders to the front of the production schedule
- Substituting similar products
- Collecting the money without shipping a product
When performing a finished goods inventory, you are counting what?
- Product in the last stage of manufacturing
- NCM products that have been painted
- Products completed with manufacturing and ready to ship
- Products sold and shipped
All shipping documents should be filed away in a __________ and in accordance to __________ policy, after shipment is complete.
- Filing cabinet / employment
- Box / customer
- Desk drawer / auditor
- Safe storage place / company
A bill of lading can also be used to determine if emergency action is needed in case of a(n) __________ during shipping.
- Flat tire
- Bad weather is experienced
- Leak or spill from a container
- Road being closed
__________ counts any materials that have been issued to a manufacturing order that have not been produced into a finished product.
- Incoming goods inventory
- Finished goods inventory
- Production floor inventory
- Work-in-progress inventory
Bursting test strength on a box certificate tells the box's ability to withstand __________ of the amount shown.
- Internal and external forces
- Water damage pressure
- Being dropped
- Product weight
Cycle counts involve verifying inventory on hand __________.
- Once per year
- On a continuous basis throughout the year
- Monthly
- As it leaves stock
Shipping weight on a bill of lading is usually expressed in __________.
- Grams
- Ounces
- Lbs or kgs
- Feet or inches
Perishable goods must be properly handled to prevent __________.
- Someone from stealing them
- Tripping hazards
- OSHA fines
- Spoilage
When documentation for product/process compliance with customer requirements is complete, the customer and all involved parties must __________.
- "Sign-off" the documentation
- Submit the documentation to a lawyer
- Submit the documentation to the supervisor for approval
- Contact OSHA regarding the next course of action
Measuring products and tracking process data is one way to apply __________ to improve quality.
- Statistical Process Control
- JIT
- Predictive maintenance
- Team members
Companies use __________ to determine how manufacturing methods are most likely to fail.
- Process failure modes and effects analysis
- Statistical Process Control
- Pareto chart
- Prototype design analysis
A supervisor should be contacted for assistance when __________.
- The marketing department issues a new product brochure
- A production employee has no trouble understanding the customer specs
- A production employee is having trouble making the product to spec
- A competitor introduces a new product line
Forklift operators contribute to maintaining product quality by __________.
- Following safety guidelines
- Following correct storage procedures
- Increasing stocking speed
- Removing unused pallets from the warehouse
When facing multiple problems at once, the first step to take is what?
- Prioritize them by greatest impact first
- Implement corrective actions
- Blame those responsible
- Identify the cause
The floor manager/supervisor is typically familiar with __________.
- Engineering procedures
- Documentation regarding customer requirements
- Marketing plans for increased sales
- Future products
A production line can run no faster than its __________ step.
- Fastest
- Slowest
- Smallest
- Shortest
Quality Assurance (QA) activities include using __________ and quality audits to measure effectiveness.
- Kanban
- Statistical process controls (SPC)
- Computer aided drafting (CAD)
- Staff meetings
One way to balance the line is to adjust each machine so __________.
- Defects are the same
- Material builds up at one station
- The cycle times are the same
- Takt time is faster
A cellular manufacturing layout is used when making a __________ of similar products.
- Small batch
- Mass batch
- Wide variety
- Small variety
__________ are used to communicate customer issues.
- Audits
- Customer communication reports
- ISO 9000 reports
- Quality reject reports
As part of a process of continuous improvement, companies use __________ to set goals to strive towards.
- Benchmarks
- Statistical Process Control
- Pareto charts
- JIT
New product design teams should perform a(n) __________ as early in the design process as possible.
- Time study
- Histogram analysis
- Design failure modes and effects analysis
- OSHA inspection
Root cause analysis is a common tool used to determine what?
- The employee responsible for making a bad part
- Which job a worker is best suited for
- Why bad parts are being produced
- The control limits on a control chart
The selection of a production area layout depends on __________.
- The number of operators available
- Timeline and budget
- Space limitations
- The type and volume of products produced
An employee should locate and assist the appropriate contact if he/she __________.
- Feels a competitor has a better process to complete the task
- Needs an extra break
- Notices a problem that would prevent customer specifications from being met
- Knows they are working on a "hot job"
When discussing SPC, the term that means the difference between maximum and minimum values in a data set is __________.
- Range
- Span
- Headroom
- Spectrum
Companies should provide an environment that encourages team members to __________.
- Criticize other team members at any time
- Provide input during the entire problem-solving process
- Attend meetings whenever they want
- Report team meetings to the boss
Increased consistency of work-flow and quality can be achieved by __________.
- Providing employees appropriate cross-training
- Reducing cost of employee benefits
- Increasing production downtime
- Maximizing employee turnover rates
To maintain a consistently high-quality product, production processes must be __________.
- Quick and rarely monitored
- Developed as cheap as possible
- Standardized and controlled
- Minimal with many operator interactions
To address customer quality issues, companies often use problem solving tools like fishbone diagrams, brainstorming, and __________.
- Root cause analysis
- Corrective action reports
- Power point
- ISO 9000 reports
