1- A part should be purchased from a single source supplier.

Purchasing a part f rom multiple suppliers can result in a variety of problems. Which of the following is not a problem caused by multiple supplier s? A) Variation in quality B) Loss of volume discounts C) Poor delivery service D) Decreased investment in equipment and training 2-Which of the following is associated with backward scheduling? A) Finite loading B) Infinite loading C) Interoperation sequencing D) Dispatch lists 3-Which of the following is/are needed in order to calculate manufacturing leadtimes? I. Routings II. Interoperation times III. Component purchase lead time A) I and II B) I and III C) II and III D) I, II, and III 4-Which of the following are true regarding operations scheduling? A) It is a short-range scheduling technique B) It is a medium-range scheduling technique C) It is a long-range scheduling technique D) None of the above

5-Which of the following is affected when input does not match output? I. Lot sizes II. Lead times III. Queue sizes A) I and II B) I and III C) II and III D) I, II, and III 6- Which of the following best describes back scheduling? A) Start with the current date and calculate the order due date by the time of e ach operation B) Rescheduling jobs where the input is greater than output C) Starting with the order due date, calculate the start date of the order by go ing back through each operation D) Eliminating capacity availability by working back through the operations 7-When orders are assigned to the factory without any restrictions on capacity, this is known as: A) smoothed capacity load. B) overloaded. C) unsmoothed load. D) lumpy capacity load. 8- own as the: A) Standard rate. B) Cycle time. C) Capacity rate. D) Setup time

9complete the job? (Round to the nearest whole day) Machine = 2 Number of operations = 2 Shis per day = 1 Hours per shi = 8 Machine ul izaon = 90% Operator efficiency = 90% 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 III. Orders are loaded for each operation, first to last A) I and II B) I and III C) II and III D) I, II, and III 11- Which of the following best defines a gateway work center? A) The work center which is the bottleneck B) The work center with the first operation C) The work center just before the final assembly D) The work center which is last

12-Which of the following statements are true regarding infinite loading? -Which of the following statements are true regarding infinite loading? I. The technique is valid although the name is misleading II. The technique is now known as capacity requirements planning III. It is also known as operations scheduling A) Iand II B) Iand III C) II and III D) I, II, and III 13-Which of the following statements are true regarding lead time? I. An overloaded factory floor increases lead time. II. Lead time will decrease when input equals output. III. Lead time will decrease if output exceeds input. A) I and II B)

I and III C) II and III D) I, II, and III 14-In a manual rescheduling process, which of the following are true? I. MRP provides information regarding which order to reschedule. II. Planners or other personnel make the changes necessary. III. Scheduled receipts are manually changed. A) Iand II B) Iand III C) II and III D) I, 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) Iand II B) Iand III C) II and III D) I, II, and III 15-In a job shop environment, which of the following are true? I. Less work in process inventory increases lead times II. Longer queues increase lead times III. More work-in-process means increased lead times A) Iand II B) Iand III C) II and III D) I, II, and III

17-Using the critical ratio, jobs which are ahead of schedule carry a ratio of-U sing the critical ratio, jobs which are ahead of schedule carry a ratio of: A) greater than 1.0. B) less than 1.0. C) equal to 1.0. D) None of the above 18-Which of the following will be true if the cumulative lead time of a product is longer than the MPS planning horizon? A) Orders for long lead time components will be released late. B) Orders for long lead time components will be released early. C) Order point can be used for the longest lead time items without affecting pri orities. D) There is no impact. 19-Which of the following statements are generally included in a routing? I. Operations to be performed and their sequence II. Work centers involved in manufacturing III. The raw materials needed to produce A) I and II B) Iand III C) II and III D) I, II, and III 20A) a job is ahead of schedule by 25%. B) a job is ahead of schedule by 75%. C) a job is behind schedule by 25%. D) a job is behind schedule by 75% 21-Which of the following are requirements for a shop order release? I. Parts availability II. Order due date III. Tooling availability A) Iand II

B) Iand III C) II and III D) I, 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 D) Work center utilization 23-Which of the following best describes mixed model scheduling? A) A regression analysis to schedule finite capacity B) A master schedule approach in a make-to-order environment C) A schedule in which products and lot sizes vary so every model is made every day D) A database system in which access is user friendly 24-Which of the following will increase machine utilization? A) Small lot sizes B) Minimal unplanned downtime C) Small work in process queues D) Making frequent product changeovers 25-The term "line balancing" means that the: A) machines are an equal distance apart. B) time taken at each work station is equal. C) high, low, and medium volume work is separated. D) setup time on each machine is equal. 26-In the electronics manufacturing industry, there is often a process step call ed 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) Constraint. 27-In process industries, such as in an oil refinery, the primary execution and control concern is: A) Linearity. B) Synchronizing the operations. C) input/output control. D) Setup times. 28-Producon order 650 isfor 500 of part3009. Fromtheroung file, itisdetermi ned that the setup me is3.0 hours and therunme is.25 hoursper piece. What isthe required capacityfor thispart? 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 s etup me on wo r k cent er 101 is 60

each. Thewaitme between each operaon is3hours and th emoveme between 101 and 102 is30 mi nutes. The waitme aer workcenter 102 is4hourswithamoveme tostorageof20minutes. What isthetotal man ufacturingleadmef orthe 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"? A) Demand planning from customers B) Execution of the material plans C) Procurement activity D) Final assembly scheduling 31-Repetitive manufacturing environments are characterized by which of the follo wing? I. Use of schedules instead of work orders II. Consistent flow of finished products III. Inventory issue transactions used for inventory

A) Iand II B) Iand III C) II and III D) I, II, and III 32-Which of the following are the result of setup reductions? B) Iand III C) II and III D) I, II, and III 32-Which of the following are the result of setup reductions? I. Increases flexibility in manufacturing II. Reduces lead times III. Allows large lot size production A) Iand II B) Iand III C) II and III D) I, II, and III 33-Preventive maintenance is important in all companies, but is usually the smal lest portion of the maintenance budget. For a lean manufacturing environment, preventive maintenance is critical for which o f the following reasons? I. Unplanned downtime due to breakdowns is avoided II. It allows the production line to produce saleable units III. It extends the useful life of equipment, thereby delaying investment in new equipment A) Iand II B) Iand III C) II and III D) I, II, and III 34-A reliable JIT system will not only simplify operations but will also simplif y transactional activity in which of the following areas? I. Purchasing II. Shop floor tracking III. Quality control A) Iand II B) Iand III C) II and III D) I, II, and III

35-An assembly line has been set up as a flow line. As each component of the fin al product is attached, the semi finished assembly is then passed to the next person on the line. This process continues u ntil the final product is completed. There are six steps in place to complete the assembly. The line works one 10 hour shi per day (assume a 60 minute hour), 5 days per week. The demand for the product is 1000 per day. -An assembly line has been set up as a flow line. As each component of the final product is attached, the semi finished assembly is then passed to the next person on the line. This process continues u ntil the final product is completed. There are six steps in place to complete the assembly. The line works one 10 hour shi per day (assume a 60 minute hour), 5 days per week. The demand for the product is 1000 per day. 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? A) Work order based B) Repetitive work order C) Visual/Kanban system D) Input/output method 37-Many times, companies will implement kanban replenishment and believe they ca n eliminate all other systems. However, kanban is not a replacement for: A) priority scheduling. B) planning. C) input/output control. D) capacity requirements planning. 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 proj ect can be undertaken to eliminate the constraint so lot sizes can be reduced further. In this example of continuous lo t 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 a

re generated. Which of the following would NOT be a benefit accruing from the use of kanban? A) 40-70% less floor space

B) Work orders have been eliminated. C) Labor reporting is eliminated. D) Less material is stored at the point of use. 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 t he rest of the work centers. The reason for this is which of the following? A) The final assembly work center is closest to the demand. B) The final quality tests are completed there. C) The forecast is usually for the finished product. 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. 42-The primary purpose of a dispatch list is to display the: A) overloaded work centers. B) priority sequence of manufacturing overload. C) outbound trucking schedule. D) inventory amounts by location. 43-Which of the following best describes a focused factory? A) A plant where all personnel understand the mission and objectives B) A plant which is established to produce a limited mix of items C) A plant which has embraced a zero-defect program

D) A plant which concentrates on one job at a time 44-All of the following are true regarding a daily dispatch list EXCEPT: A) Due dates are taken from MPS B) Due dates from MRP may be modified

C) It allows the centralization of shop floor control D) It is generated in priority sequence 45-Which of the following are generally in the shop packet? It allows the centralization of shop floor control D) It is generated in priority sequence 45-Which of the following are generally in the shop packet? I. Operation sheets II. Pick lists III. Move tickets A) Iand II B) Iand III C) II and III D) I, II, and III 46-A job status report would show: A) costs accumulated for the job. B) the input and output of every work center. C) the plan for completing a job and the progress versus the plan. D) the job priority at each work center. 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 prior ity 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: A) in jobs where imaging is necessary. B) in highly repetitive jobs not suited for humans. C) because they cost less than direct labor. D) to provide a high tech environment. 49-The term "linearity" means: A) the line capacity is balanced from beginning to end. B) production is at a constant or level rate.

C) a single source supplies each componentource supplies each component. D) the master schedule is not overloaded. 50-In the Kanban system, lead time reduction is the responsibility of: A) Supervisors B) Materials personnel C) Direct labor 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) Iand II B) Iand III C) II and III D) I, II, and III 52-If a work center is becoming a bottleneck and throughput time is getting long er, which of the following could be a solution? I. Decrease the input II. Increase the planned lead times III. Increase the capacity A) Iand II B) Iand III C) II and III D) I, 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 ne arest 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 D) Not enough data 55-If the hours worked were expanded to a 12 hour shi, wh at wo ul d the avai la bl e capaci ty be? (Rounded to t he nearest -If the weekly load on the work center is 72 hours, the work center is: A) Overloaded B) Underloaded C) In balance D) Not enough data 55-If the hours worked were expanded to a 12 hour shi, wh at wo ul d the avai la bl 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 a vai labl e capaci ty be? (Rounded to the nearest standard hour.) A) 60 B) 72 C) 84 D) 96 57-Which of the following could be causes of idle time? I. Maintenance II. Setup III. Training A) Iand II B) Iand III C) II and III D) I, II, and III 58-When a set-up procedure occurs while a machine is not operating, it is called : A) external setup time. B) interoperation time. C) internal setup time. D) gapped time.

59 -Which of the following statements are true regarding Just-in-Time production ? -Which of the following statements are true regarding Just-in-Time production? I. Only refers to the delivery of products when needed II. Refers to the elimination of waste -"If it doesn't add value, it's waste; el iminate it" III. It is a pull system A) Iand II B) Iand III C) II and III D) I, II, and III 60-The phrase "one less at a time" refers to which of the following? A) Reducing the number of suppliers necessary to produce the product B) The reduction of direct labor caused by the creation of manufacturing cells C) The process of gradually reducing lot sizes in manufacturing to eliminate obs tacles D) Establishing a flow line in which the production rate is one at a time 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: I. Reducing setup times (quick changeover) II. Reducing or eliminating queue times III. Lowering defects towards a zero goal IV. Cross-training workers A) Iand III B) I, II, and III C) II, III, and IV D) I, II, III, and IV 62-All of the following are part of starting a Just-in-Time implementation EXCEP T: A) Conduct some general JIT education B) Complete a detailed implementation plan for the complete project C) Pick a pilot project D) Review pilot project as a learning experiment 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: A) work center which constrains the flow. B) signal system which links work centers. C) tool for quick set-up. 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) Iand II B) II and IV C) Iand IV D) I, II, III, and IV 66-Which of the following would best describe the term poka-yoke? A) Mistake proofing a process B) Setups in less than 10 minutes C) Lot size equal to one D) Kanban sizing methodology 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 failur e, appraisal, and external failure. Which of the following would NOT be considered an appraisal cost? A) Inspection personnel B) Test equipment in the QC lab

C) Scrap D) Gauge calibration 69& 70 Based On the Following Information D) Gauge calibration 69& 70 Based On the Following Information 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 Pe riod 4 in order to reduce the backlog? A) 130 B) 150 C) 160 D) Any of the above 71-Quality is best defined as: A) zero defects. B) conformance to requirements. C) less than .1% tolerance. D) within range on the SPC chart. 72-The term, "empower", can best be defined by which of the following? A) The right to hire and terminate personnel B) Authorize the payment of invoices

C) Enable or give authority D) Dictate the rules 73-Which of the following are process analysis tools? able or give authority D) Dictate the rules 73-Which of the following are process analysis tools? I. Flowcharts II. Scatter diagrams III. GANTT chart A) I B) Iand II C) Iand III D) I, II, and III 74-When a quality problem surfaces within a process, the problem can be identifi ed and analyzed using a cause and effect diagram. This cause and effect analysis is usually made using a: A) fishbone diagram. B) SPC chart. C) force field analysis. D) Pareto analysis. 75-In order to certify a supplier, a customer will send an audit team to the sup plier site to conduct a quality audit on the supplier. While the audit team members may vary from company to company, which o f the following functions would not be included in the customer audit team? A) Buyer B) Quality engineer C) Marketing person D) Materials manager