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WorksheetsOperations Management with TQM Removal Examination
Total questions: 74
Worksheet time: 2hrs 11mins
The ability of an organization to produce goods or services that have some uniqueness in their characteristics is
mass production
time-based competition
competing on productivity
competing on flexibility
competing on differentiation
A strategy is a(n)
set of opportunities in the marketplace
broad statement of purpose
simulation used to test various product line options
plan for cost reduction
action plan to achieve the mission
The ability of an organization to produce services that, by utilizing the consumer's five senses, have some uniqueness in their characteristics is
mass production
time-based competition
differentiation
flexible response
experience differentiation
Standardization is an appropriate strategy in which stage of the product life cycle?
introduction
growth
maturity
decline
retirement
The stage in the product life cycle at which it is a poor time to change quality is
introduction
growth
maturity
decline
incubation
The three major subdivisions of the product decision are
selection, definition, and design
goods, services, and hybrids
strategy, tactics, and operations
cost, differentiation, and speed of response
legislative, judicial, and executive
A product's life cycle is divided into four stages, which are
introduction, growth, saturation, and maturity
introduction, growth, stability, and decline
introduction, maturity, saturation, and decline
introduction, growth, maturity, and decline
none of the above
Quality function deployment (QFD)
determines what will satisfy the customer
translates customer desires into the target design
is used early in the design process
is used to determine where to deploy quality efforts
all of the above
A graphic technique for defining the relationship between customer desires and product/service is
Product Lifecycle Management
the House of Quality
the moment of truth
the assembly drawing
the product development team
Modern ATM machines are an automated example of a service design that
reduces customer interaction
modularizes the service
delays service customization
has no moment of truth
has insufficient quality function deployment
Keeping a product generic as long as possible before customizing is known as
postponement
keiretsu
channel assembly
forward integration
backward integration
Japanese manufacturers often take a middle ground between purchasing from a few suppliers and vertical integration. This approach is
kanban
keiretsu
samurai
poka-yoke
kaizen
It is a supply chain phenomenon where orders to suppliers tend to have a larger variability than sales to buyers, which results in an amplified demand variability upstream
kanban
keiretsu
bullwhip effect
poka-yoke
kaizen
It is a logistics procedure where products from a supplier or manufacturing plant are distributed directly to a customer or retail chain with marginal to no handling or storage time
postponement
keiretsu
cross docking
outsourcing
networking
It is an approach that seeks efficiency of operations through the integration of all materials acquisition, movement, and storage activities.
Vendor Management
Demand Management
Supply Management
Logistics Management
Capacity Management
Disaggregation
breaks the aggregate plan into greater detail
transforms the master production schedule into an aggregate plan
calculates the optimal price points for yield management
converts product schedules and labor assignments to a facility-wide plan
is an assumption required for the use of the transportation model in aggregate planning
Which of these is among the demand options of aggregate planning?
subcontracting
back-ordering during high-demand periods
changing inventory levels
varying workforce size
All of the above are demand options.
Aggregate planning for service firms that provide intangible output deals mainly with
smoothing the production rate and finding the optimal size of the workforce
yield management
centralized purchasing
centralized production
planning for human resource requirements and managing demand
Which of the following aggregate planning strategies might direct your client to a competitor?
using part-time workers
subcontracting
changing inventory level
varying production rates through overtime or idle time
varying work force size by hiring or layoffs
Which of these aggregate planning strategies adjusts capacity to match demand?
back ordering
using part-time workers
counterseasonal product mixing
changing price
None of the above is a capacity option.
"Employees cannot produce goods that on average exceed the quality of what the process is capable of producing" expresses a basic element in the writings of
Vilfredo Pareto
Armand Feigenbaum
Joseph M. Juran
W. Edwards Deming
Philip B. Crosby
"Quality Is Free," meaning that the costs of poor quality have been understated, is the work of
W. Edwards Deming
Joseph M. Juran
Philip B. Crosby
Crosby, Stills, and Nash
Armand Feigenbaum
"Cause and Effect or Fishbone diagram" as a quality control tool is the work of
W. Edwards Deming
Joseph M. Juran
Philip B. Crosby
Kaoru Ishikawa
Armand Feigenbaum
If 1 million passengers pass through the St. Louis Airport with checked baggage each month, a successful Six Sigma program for baggage handling would result in how many passengers with misplaced luggage?
3.4
6.0
34
2700
6 times the monthly standard deviation of passengers
The process improvement technique that sorts the "vital few" from the "trivial many" is
Taguchi analysis
Pareto analysis
benchmarking
Deming analysis
Yamaguchi analysis
"Kaizen" is a Japanese term meaning
a foolproof mechanism
just-in-time (JIT)
a fishbone diagram
setting standards
continuous improvement
Which one of the following is not a benefit of the implementation of JIT?
cost reduction
variability increase
rapid throughput
quality improvement
rework reduction
Which of the following is specifically characterized by a focus on continuous improvement, respect for people, and standard work practices?
Just-in-time (JIT)
Toyota Production System (TPS)
Lean operations
Material requirements planning (MRP)
kanban
Which of the following is specifically characterized by continuous and forced problem solving via a focus on throughput and reduced inventory?
Just-in-time (JIT)
Toyota Production System (TPS)
Lean operations
Material requirements planning (MRP)
kanban
Which of the following is specifically characterized by the elimination of waste through a focus on exactly what the customer wants?
Just-in-time (JIT)
Toyota Production System (TPS)
Lean operations
Material requirements planning (MRP)
kanban
The word "kanban" means
low inventory
employee empowerment
card
continuous improvement
lot size of one
This means overburden because a process, system, facility designed beyond the physical capacities of employee or equipment.
muda
mura
muri
mupa
musi
It is a concept in lean manufacturing meaning autonomation which guarantees that machines as well as their operators can shut down a process when anomalies are detected.
gemba gembutsu
jidoka
ikigai
poka yoke
kanban
It is the outcome of effective maintenance, which gauges an asset's ability to function as intended for a specific period.
availability
maintainability
reliability
quality
overall equipment effectiveness
A foundry produces circular utility access hatches (manhole covers). Currently, 120 covers are produced in a 10-hour shift. If labor productivity can be increased by 20%, it would then be
14.4 covers/hr
24 covers/hr
240 valves/hr
1200 covers/hr
none of the above
The Dulac Box plant produces 500 cypress packing boxes in two 10-hour shifts. What is the productivity of the plant?
25 boxes/hr
50 boxes/hr
5000 boxes/hr
none of the above
not enough data to determine productivity
The Dulac Box plant produces 500 cypress packing boxes in two 10-hour shifts. Due to higher demand, they have decided to operate three 8-hour shifts instead. They are now able to produce 600 boxes per day. What has happened to production?
It has increased by 50 sets/shift.
It has increased by 37.5 sets/hr.
It has increased by 20%.
It has decreased by 8.3%.
It has decreased by 9.1%.
What is the approximate forecast for May using a four-month moving average?
38
42
43
44
47
John's House of Pancakes uses a weighted moving average method to forecast pancake sales. It assigns a weight of 5 to the previous month's demand, 3 to demand two months ago, and 1 to demand three months ago. If sales amounted to 1000 pancakes in May, 2200 pancakes in June, and 3000 pancakes in July, what should be the forecast for August?
2400
2511
2067
3767
1622
A forecasting method has produced the following over the past five months. What is the mean absolute deviation?
-0.2
-1.0
0.0
1.2
8.6
The last four months of sales were 8, 10, 15, and 9 units. The last four forecasts were 5, 6, 11, and 12 units. The Mean Absolute Deviation (MAD) is
2
-10
3.5
9
10.5
Demand for a certain product is forecast to be 800 units per month, averaged over all 12 months of the year. The product follows a seasonal pattern, for which the January monthly index is 1.25. What is the seasonally-adjusted sales forecast for January?
640 units
798.75 units
800 units
1000 units
cannot be calculated with the information given
A seasonal index for a monthly series is about to be calculated on the basis of three years' accumulation of data. The three previous July values were 110, 150, and 130. The average over all months is 190. The approximate seasonal index for July is
0.487
0.684
1.462
2.053
cannot be calculated with the information given
A time series trend equation is 25.3 + 2.1 X. What is your forecast for period 7?
23.2
25.3
27.4
40.0
cannot be determined
The Academic Computing Center has five trainers available in its computer labs to provide training sessions to students. Assume that the capacity of the system is 1900 students per semester and the utilization is 90%. If the number of students who actually got their orientation session is 1500, what is the efficiency of the system?
1350 students
1710 students
75%
87.7%
90%
Christopher's Cranks uses a machine that can produce 100 cranks per hour. The firm operates 12 hours per day, five days per week. Due to regularly scheduled preventive maintenance, the firm expects the machine to be running during approximately 95% of the available time. Based on experience with other products, the firm expects to achieve an efficiency level for the cranks of 85%. What is the expected weekly output of cranks for this company?
5100
5700
4845
969
6783
The staff training center at a large regional hospital provides training sessions in CPR to all employees. Assume that the capacity of this training system was designed to be 1200 employees per year. Since the training center was first put in use, the program has become more complex, so that 1050 now represents the most employees that can be trained per year. In the past year, 950 employees were trained. The efficiency of this system is approximately _____ and its utilization is approximately _____.
79.2 percent; 90.5 percent
90.5 percent; 79.2 percent
87.5 percent; 950 employees
950 employees; 1050 employees
110.5 percent; 114.3 percent
Fabricators, Inc. wants to increase capacity by adding a new machine. The fixed costs for machine A are $90,000, and its variable cost is $15 per unit. The revenue is $21 per unit. The break-even point for machine A is
$90,000 dollars
90,000 units
$15,000 dollars
15,000 units
cannot be calculated from the information provided
Process A has fixed costs of $1000 and variable costs of $5 per unit. Process B has fixed costs of $500 and variable costs of $15 per unit. The crossover point between process A and process B is
50 units
200 units
$2,500
$5,000
$9,500
A production line is to be designed for a job with four tasks. The task times are 2.4 minutes, 1.4 minutes, 0.9 minutes, and 1.7 minutes. The maximum cycle time is ______ and the minimum cycle time is ______ minutes.
1.8; 1.4
1.6; 0.9
6.4; 2.4
2.4; 0.9
none of these
An assembly line consists of 21 tasks grouped into 5 workstations. The sum of the 21 task times is 85 minutes. Cycle time for the line is 20 minutes. The efficiency of this line is
4.2 percent
17 percent
85 percent
100 percent
none of the above
A production line is to be designed to make 500 El-More dolls per day. Each doll requires 11 activities totaling 16 minutes of work. The factory operates 750 minutes per day. The cycle time for this assembly line is
one-half minute
one and one-half minutes
two minutes
5,500 minutes
cannot be determined from the information given
Four hundred and eighty minutes of production time are available per day. The schedule calls for the production of 80 units per day. Each unit of the product requires 30 minutes of work. What is the theoretical minimum number of workstations?
2
3
4
5
6
East Texas Seasonings is preparing to build one processing center to serve its four sources of seasonings. The four source locations are at coordinates shown below. Also, the volume from each source is provided. What is the center of gravity?
X = 28.125; Y = 31.25
X = 22000; Y = 24000
X = 27.5; Y = 40
center of gravity = 28
none of the above
A full-service restaurant is considering opening a new facility in a specific city. The table below shows its ratings of four factors at each of two potential sites. The score for Gary Mall is _____ and the score for Belt Line is ______.
120; 120
22; 24
18; 120
34; 28
none of the above
A firm is considering two location alternatives. At location A, fixed costs would be $4,000,000 per year, and variable costs 0.30 per unit. At alternative B, fixed costs would be $3,600,000 per year, with variable costs of $0.35 per unit. If demand is expected to be 10 million units, which plant offers the lowest total cost?
Plant A, because it is cheaper than Plant B for all volumes under 8,000,000 units
Plant B, because it is cheaper than Plant A for all volumes over 8,000,000 units
Plant A, because it is cheaper than Plant B for all volumes
Plant B, because it has the lower variable cost per unit
neither Plant A nor Plant B, because the crossover point is at 10 million units
A county wants to build one centrally-located processing facility to serve the county's four recycling drop-off locations. The four drop-offs have characteristics as given in the table below. What is the approximate center of gravity of these four locations?
4.75, 6.04
17, 24
33.5, 135.4
6, 4.25
570, 725
A certain type of computer costs $1,000, and the annual holding cost is 25%. Annual demand is 10,000 units, and the order cost is $150 per order. What is the approximate economic order quantity?
16
70
110
183
600
The assumptions of the production order quantity model are met in a situation where annual demand is 3650 units, setup cost is $50, holding cost is $12 per unit per year, the daily demand rate is 10 and the daily production rate is 100. The production order quantity for this problem is approximately
139
174
184
365
548
A local distributor for a national tire company expects to sell approximately 9,600 radial tires of a certain size and tread design next year. Annual carrying cost is $16 per tire, and ordering cost is $75. The distributor operates 288 days a year. What is the Economic Order Quantity?
310
300
30
32
334
What is the reorder point for Problem No. 60 if the leadtime is 5 days?
34
167
300
200
75
Given the following bill of material If the demand for product A is 50 units, what will be the gross requirement for component E?
4
100
200
250
300
Each X requires 2 of component Y; each Y requires 4 of part Z. The lead time for assembly of X is 1 week. The lead time for the manufacture of Y is 1 week. The lead time for the procurement of Z is 6 weeks. The cumulative lead time for X is _____ weeks.
6
7
8
10
cannot be determined
The MPS calls for 50 units of Product A and 60 of B. There are currently 25 of Product B on hand. Each A requires 2 of Part C; each B requires 5 of C. There are 160 units of C available. The net requirements for C are
115
175
240
690
700
Given that the machine availability is 88.75%, the performance is 90.25%, and the quality rating is 98.5%, what is the overall equipment effectiveness?
92.50%
78.90%
88.16%
100%
cannot be determined
Given the following bill of material If the demand for product A is 30 units, and there are 10 units of B on hand and none of C, how many units of part D will be needed?
3
40
70
90
110
Five jobs are waiting to be processed. Their processing times and due dates are given below. Using the earliest due date dispatching rule, in which order should the jobs be processed?
C, E, A, D, B
A, B, C, D, E
B, D, A, E, C
C, B, A, E, D
none of the above
Eight jobs have been sequenced at a single work center. Total processing time for the eight jobs is 34 hours and total flow time for the sequence is 85 hours. For this schedule, utilization is ______ and average jobs in the system is ________.
100 percent; 10.625
low; .0941
0.400 or 40 percent; 2.5
0.235 or 23.5 percent; 4.25
maximized; minimized
What is the reliability of the system shown on the following figure?
87.32%
76.24%
98.39%
96.81%
98.95%
Five jobs are waiting to be processed through two work centers. Their processing time (in minutes) at each work center is contained in the following table. Each job requires work center Sigma before work center Delta. According to Johnson's rule, what sequence of jobs will minimize the completion time for all jobs?
R-S-T-U-V
S-V-T-R-U
S-U-T-V-R
V-R-U-S-T
none of the above
Five jobs are waiting to be processed through two work centers. Their processing time (in minutes) at each work center is contained in the table below. Each job requires work center Alpha before work center Beta. According to Johnson's rule, what is the sequence of the job to minimize completion time?
U-V-S-T-R
R-T-S-V-U
U-R-S-T-V
R-T-SU-V
U-S-V-T-R
According to Johnson's rule, what is the minimum time for completion of all jobs in problem no. 71?
225
175
240
200
none of the above
Three jobs are to be assigned to three machines. Cost for each job-machine combination appears in the table below. What is the optimum assignment of jobs to minimize cost?
1-C; 2-B; 3-A
1-C; 2-A; 3-B
1-B; 2-C; 3-A
1-B; 2-A; 3-C
1-A; 2-C; 3-B
What is the cost of optimal assignment in problem 73?
26
25
24
22
20
