Session 1 1.- Business planning is _______________ d) completed by top management 2.- Closed-loop means_________________ d) Activities are integrated 3.

- Which of the following represents the four-step process for planning and control? c) Plan, execute, measure, correct. 4.- The objectives of the MPC system are maximizing customer service, limiting inventory investment, and which of the following? b) Maintaining high operating efficiencies 5.- Planning interfaces are_______________ a) Interactions that facilitate the planning and control of production activity. 6.- Which of the following best defines the process of master scheduling? b) Creating, reviewing, and approving the master production schedule. 7.- the connections between production activity control and the rest of the MPC system are which of the following? d) Capacity and material plans 8.- Cellular manufacturing can also be described as ___________________ a)type of process 9.- Which of the following is a type of flow manufacturing d) all of the above (repetitive, continuous, batch flow) 10.- Which of the following best defines the process of capacity requirements planning? a) Determining in detail the amount of labor and machine resources required to accomplish the requirements schedule.

Session 2 1.- Planned and actual lead times_____________________ b) should be compared for corrective actions. 2.- Which of the following is an informal method of sequencing production that disrupts priority sequencing? d) informal hot lists 3.- Which of the following best describes a work center with actual output greater than planned output? b)running ahead of schedule. 4.- Which of the following best describes finite loading d) limits loads to available resources 5.- Which of the following is a project scheduling technique? c) Critical path method (CPM) 6.- Which of the following best describes mixed-model scheduling ? a) Aims to produce each according to daily demand. 7.- Priorities must be established and revised to reflect which of the following ? d)all of the above (shop conditions, material availability, customer needs) 8.- The benefits of preventive and predictive maintenance are increased flexibility, flow improvements, and which of the following? a) reduced material handling 9.- The critical path method is a net work scheduling technique for determining which of the following ? b) expected project completion. 10 .- Which of the following best describes synchronous scheduling? c) output rate is determined by the system constraint

Session 3.1.- within a push system , products are released and pushed through production based on which of the following ? a) production schedule 2.- Which of the following is an assumption within a push system? c)the receiving work center is ready for the material when it arrives. 3.- Authorization of order release is based on which of the following ? d) all of the above (current priority, availability of material and tooling, planned orders in the MRP output) 4.- Resource availability must be checked in order to prevent which of the following ? d) Increased queues. 5.- Material availability checks consider____________________ d)balances on hand and quantities allocated to other orders 6.- Dispatch lists_______________ a)may consider more than one factor to establish job sequences at a work center 7.- Material reporting includes each of the following except d)actual setup and run times 8.- Which of the following are hurdles to effective shop floor control ? d) all of the above ( lack of valid data, lack of good management and measurement by shop managers, lack of valid due dates) 9.- When applied to dispatching, priority determination techniques must have four characteristics. Which of the following is one of the characteristics? c) Simplicity 10.- Which of the following is a reason to avoid staging? a ) inaccurate inventory data.

Session 4 1. Which explanation best describes why a pull system works well in a structured environment? A)The source of incoming material is consistent 2. Which is an objective of a pull system? D)Limit total inventory 3. A pull system can be applied in which of the following environments? C) Any environment where production activities fall within defined limits 4. Which of the following statements is true? C) A pull system can operate autonomously and has low data processing and communicating expenses. 5. Which of the following is a characteristic of a pull system? B) Standard lot size 6. Which is a characteristic of true Kanban Methology? C)Both what and when to replenish 7. Brand-name Kanban cards authorize C) Both what and when to replenish 8. Which of the following are rules for a two-card kanban system? D) All of the above: Use of one card per container, Return the move card immediately, Leave the production card at supply point. 9. Which of the following statements is a reason to simplify documentation in a pull system? B)Detailed routing information is not necessary 10. Which characteristic is more desirable for controlling production within a pull system? A)Flexibility Capability

Sesin 5 1. Which explanation best describes the major cause of customer-supplier disputes? D) Poor communication and subsequent cooperation to solve problems. 2. The focus of an ideal customer-supplier relationship is on learning which one of the following? D) All of the above: Concerns, capabilities, wants. 3. For optimal levels of information sharing between the customer and supplier, which situation should be in place? C) Supplier is fully integrated into customers operations 4. What type of data communication should be utilized to control the shop floor? B) Timely and accurate 5. Which of the following groups reflects principles of effective item identification? B)Uniqueness, uniformity in length and composition, expansion 6. Which of the following best represents an objective of controlling storage a) minimizing non value added time 7. effective use of containerization facilitates which of the following ? d)all of the above (transportation, effective storage practices, material use) 8. which of the following inventory location methods requires the use of a locator file to identify parts locations? a) random location 9. If inventory is stored near the operation where it is used, what storage technique is being utilized? b)point of use 10. In a lean/JIT environment, reducing shipment size and receiving and delivering shipments more frequently will result in which of the following? a)reducing total acquisition costs

Session 6 1. Cause-and-effect analyses are made with the help of which of the following? a) Fishbone chart

2. Quality at the source suggests that the quality of the product is determined at the instant the product is made. Is this is true, then which of the following is also true? b) Inspection is not necessary

3. Which of the following statements is true? c) Quality is considered necessary for survival

4. Who must be involved with continuous improvement efforts? d) All personnel 5. Before beginning a continuous improvement program, you must consider the industry, product lines, supplier base, human resource capabilities, customers organizational culture and which of the following? c) Technical capabilities 6. Waste can be defined as: D ) The use of resources in excess of the theoretical minimum

7. Employee empowerment is the practice of c) Giving nonmanagerial employees the responsibility to make decisions 8. A small group of people who normally work as a unit and meet frequently to uncover and solve problems concerning the quality of items produced is most likely called a: b) Quality circle 9. Which of the following is NOT a quality management planning tool? a) Asset diagram 10. A Pareto chart can be used to: c) Eliminate visual signs that alert workers to defective parts

Session 7 1. Recognize process improvement opportunities may be difficult because: a) They are part of daily routine 2. Reducing los size to achieve which of the following? c) Improved process flows 3. In the ideal organized work environment, which of the following is true? b) Movement is minimized 4. Which of the following best describes the functions of the one less at a time process? b) Expose constraints by putting pressure on the system 5. Which of the following must be reduced in order to reduce the total amount of elapsed movement time from supplier to customer? d) All of the above 6. Which of the following is a technique that helps to create an effective inventory reporting system? d) Taguchi method 7. Which of the following explains why reporting becomes difficult in lean/JIT environment? b) Each production element is too short to measure 8. Which of the following steps comprise the process for carrying out of the project-by-project approach? d) Verifying the project need and mission, diagnosing the causes, providing a remedy and providing its effectiveness, dealing with resistance to change, and instituting controls to hold gains 9. Which of the following result from rapid movement of material? b) Evaluating the problem, completing the housekeeping checklist, and ensuring that the kanban levels are marked. 10. Dramatic setup reductions will be achieved by which of the following? d) Using the Pareto chart

Session 8

1. Customer satisfactions is achieved through which two components? d) Product features and freedom from deficiencies

2. Which of the following is not a quality perspective? c) Purchasing

3. A statistical control chart distinguishes between special- and common-cause variations through which of the following? d) Control limits

4. Which of the following best explains the concept of variation? d) No two items are exactly alike

5. The difference between special- and common-cause variation is which of the following? a) The source of special- cause variation is assignable, whereas the source of common-cause variation is random

6. Which of the following best describes acceptance sampling? d) The process of sampling a portion of goods for inspection

7. SPC is a technique that a) Helps prevent defects from occurring a while a product is being produced

8. Which of the following is calculates using statistics? c) Control limits

9. A process capability analysis provides which of the following? a) Quantified prediction of process adequacy

10. Which of the following best describes the basis of product acceptance? a) Disposition and quality of the product

PREGUNTAS DEL DISCO MOD 4

1. Which of the following best describes the results of total quality control?

A. B. C. D.

Statistical tests of production identify sources of defects. The number of inspection stations is decreased in the production process. The product meets the expectations of the customer. The cost of scrap and rework is below budget.

2. An operator falls behind the flow and a small bottleneck occurs at a workstation. The operator switches on the signal light, and the two operators at the adjacent workstation immediately move in to help. Soon, the bottleneck is relieved, and the two return to their workstations. The procedure described above includes examples of all of the following EXCEPT

A. B. C. D.

leveling teamwork visibility flexibility

3. U-shaped cells that group dissimilar machines to perform various operations on a part result in reduction of all of the following EXCEPT

A. B. C. D.

travel distances machine downtime in-process inventory lead times

4. End-of-line inspection often fails to improve quality for which of the following reasons?

A. B. C. D.

It requires extensive personnel. It disregards the causes of poor quality. It excludes quality circles. Inspectors do not understand quality improvement techniques.

5. In repetitive manufacturing, standardization of products can be achieved through which two of the following? I. Commonality of parts II. Modularity of design III. Supplier conformance to quality standards IV. Standard costing practices

A. B. C. D.

I and II I and III II and III II and IV

6. Long-term agreements with suppliers may include which of the following terms?

I. Part quantities II. Planned dollar volume III. Inventory liability IV. Frequency of planning data

A. B. C. D.

IV only II and III only I, II, and III only I, II, III, and IV

7. Reducing queues achieves all of the following EXCEPT A. B. C. D. shortened production lead times quicker feedback about quality problems improved process capability reduced inventory investment

8. A focused factory is usually characterized by which two of the following? I. Restricted product variety II. Decreased attention to detail III Layout by function IV. Logical flow patterns

A. B. C. D.

I and III I and IV II and III II and IV

9. Which of the following are the desired results of removing a kanban card from between two steps of a smooth flowing process? I. Reduced inventory level II. The insertion of a kanban card to replace the one removed III. To expose problems A. B. C. D. I and II only I and III only II and III only I, II, and III

10. In the implementation of lean/Just-in-Time, which of the following is the most significant change for the accounting function?

A. B. C. D.

Cellular processes no longer report every operation to accounting. Budgeted scrap and rework costs that create variances are reduced. Physical inventory of work-in-process inventory is more time-consuming. Costs of incentive programs increase.

11. The initial objective of a process capability study is to

A. B.

improve process utilization determine process variance

C. D.

reduce process time reduce process queues

12. Lean/JIT training should increase capabilities of operations supervisors to do all of the following EXCEPT

A. B. C. D.

balance workload in cells calculate number of kanbans maintain high equipment utilization coordinate preventive maintenance

13. Company A is implementing a lean/JIT manufacturing approach and has decided to use the necessary process control techniques. Which of the following groups should most actively use them?

A. B. C. D.

the shop floor workforce the quality control department executive management the industrial engineering department

14. The use of failsafe work methods implies that a company has

A. B. C. D.

sophisticated, in-line inspection equipment statistical process control highly trained workers immediate detection of errors

15. The cell layout shows which two of the following? I. Project time line II. Material and operator flow III. Quick-hit list IV. Cycle time and takt time

A. B. C. D.

I and III I and IV II and III II and IV

16. Which of the following software capabilities is used so that transaction costs are minimized when lean/Just-in-Time is implemented in an MRP environment?

A. B. C. D.

pegging backflushing forecasting lot sizing

17. Sustaining process changes include all of the following EXCEPT

A. B. C. D.

deploy housekeeping audit checklists (i.e., 5S) encourage continuous improvement activities make team members work rather than updating daily the shop loor performance measures clean and check equipment on a daily basis

18. Customer-oriented manufacturing performance measures include all of the following EXCEPT

A. B. C. D.

service parts fill rate cost variances product quality delivery performance

19. All of the following elements are required for a successful change to the lean/JIT approach EXCEPT

A. B. C. D.

organizationwide awareness of a need for elimination of waste people who are willing to work hard and methodologically a past history of excellence in manufacturing commitment for continued improvement

20.To which of the following types of delivery can kanban methods be applied? I. Within a plant II. From plant to plant III. From suppliers to plants

A. B. C. D.

I only I and II only II and III only I, II, and III

21. Pareto analysis is included in training so that employees may use it to identify which of the following? A. B. C. D. the most frequently occurring defects out-of-control operations the customer base for marketing the volume of work through the plant

22. Which of the following will occur when material requirements planning (MRP) and Justin-Time (JIT) are integrated?

A.

MRP will continue to support both operations planning and control.

B. MRP will continue to support operations planning, and JIT pull systems will support operations control. C. MRP will continue to support operations control, and JIT pull systems will support operations planning. D. JIT pull systems will eliminate the need for MRP.

23. Which of the following are benefits of statistical process control? I. Fewer inspection steps II. Less preventive maintenance III. Quick recognition of problems IV. Quick recognition of the effects of correction

A. B. C. D.

I and IV only II and III only I, III, and IV only I, II, III, and IV

24. High-quality production is best achieved by doing which of the following?

A. B. C. D.

reporting production quality information online establishing employee ownership of quality increasing the number of quality control inspection personnel using process control charts

25. Material is pulled into a final assembly area from feeding operations

A. B. C. D.

when production is completed as it is needed when material handling equipment is available when material balance is zero

26. Which of the following actions is most likely to produce a high degree of sustained inventory data integrity?

A. B. C. D.

increasing frequency of cycle counts changing cycle counting methods periodically making periodic physical inventories resolving problems exposed by cycle counting

27. Which of the following would be manufactured in a continuous-production process?

A. B. C. D.

combines clothing vitamins gasoline

28. Which of the following statements is (are) true about pull systems for distribution inventory control? I. They are useful when geographical demand patterns can be forecast accurately at the factory. II. They are more appropriate with low-value, high-volume items.

III. They are important when goods are frequently on allocation from the factory.

A. B. C. D.

II only III only I and III only II and III only

29. Which of the following systems would be most appropriate for managing an inventory of motors purchased by an appliance manufacturer for use in the assembly of several models of an automatic dishwasher?

A. B. C. D.

two-bin replenishment system MRP system fixed order quantity, EOQ, reorder point system fixed interval, periodic ordering system

30. Which of the following statements is true about obtaining a high level of accuracy for inventory records?

A. B. C. D.

It would usually lead to a reduction of inventory levels. It is not necessary to achieve because of safety stocks and safety lead time. It would result in savings that are likely to be small and difficult to determine. It is probably impossible to achieve and will be costly to obtain.

31. In environments using backflush inventory relief, perpetual on-hand inventory counts are relieved when

A. B. C. D.

planned orders for the parent items are created by MRP a work order for the parent item is generated production against the parent item is reported the parent item is shipped to a customer

32. The value of work-in-process inventory is LEAST affected by which of the following?

A. B. C. D.

process time lot sizing queue time MRP processing frequency

33. Measurement of customer service delivery performance should be based on which of the following considerations?

A. B.

Whether the company operates on a fiscal or calendar month. The result of the measurement should be easily understood by management.

C. The delivery measurement performance should focus on how well the shipping dollar budget is met. D. The measurement should indicate overall customer satisfaction with a product.

34. Inventory control can be improved by adopting which of the following storeroom practices? I. Calculating EOQs to determine quantities to issue II. Initiating a cycle-counting system III. Making the storeroom off-limits to all except storeroom personnel IV. Maintaining parallel record systems to cross-check balances

A. B. C. D.

I and II only II and III only III and IV only I, III, and IV only

35. The main objective of line balancing in an assembly operation is to

A. B. C. D.

provide maximum mobility of operators between assembly lines minimize the total number of parts required for each assembly line develop work standards for cost-estimating purposes distribute the work to maximize line output

36. Increased supplier lead times prompt the customer to

A. B.

carry smaller safety stocks carry larger safety stocks

C. D.

release fewer orders to the suppliers do less expediting with the supplier

37. If a job shop automates its tool-changing process to reduce setup times, the change will result in an increase in which of the following?

A. B. C. D.

annual number of shop orders queue lead time lot size

38. When Pareto's Law (80-20 rule) is used to reduce lead time, which of the following elements should be addressed first?

A. B. C. D.

move time queue time setup time run time

39. When expediting purchased parts that are needed from the supplier before the original due date, a buyer should first try to do which of the following?

A. B. C. D.

buy all the parts from an alternate source offer to de-expedite another part that is needed later than the original due date offer to pay a premium increase safety lead time by one week

Item 40 is based on the following information: Quantity = 100 pieces Cycle Queue Time per Setup (Days) piece (Hours) (Hours) 1 .1 2 2 .1 2 2 .5 5 2 .3 2 2 .4 1

10 Saw 20 Face 30 Turn 40 Drill 50 Grind

A one-shift operation, 8 hours/day with 100% efficiency should be assumed. 40. If the order in the job shop described above starts on the beginning of day 1, when would it be finished?

A. B. C. D.

day 20 day 23 day 28 day 30

Questions 41 and 42 refer to the following diagram. Assembly A consists of a number of parts and subassemblies as indicated. The total lead time, with no inventory on hand or in process, is fixed at 8 periods.

41. If the current date is the beginning of Period 1 and the customer request date is Period 10, the latest release of Parts D and 2 must occur

A. B. C. D.

in Periods 1 and 2 respectively in Periods 2 and 3 respectively in Periods 3 and 4 respectively after Period 4

42. If the current date is the beginning of Period 4, scheduling Assembly A for the earliest completion date is an example of

A. B.

forward scheduling backward scheduling

C. D.

block scheduling critical ratio scheduling

43. Effective shop floor controls can improve customer service in which of the following ways? I. By reducing lead time II. By replenishing finished inventory on schedule III. By improving component availability A. B. C. D. I only I and III only II and III only I, II, and III

44. Inventory shrinkage has occurred when physical inventory dollars are less than book inventory dollars. What is the effect of inventory shrinkage on a company's profit and loss statement?

A. B. C. D.

decrease in the cost of goods manufactured increase in inventory dollars decrease in sales dollars decrease in profits

45. Under the group technology concept, which of the following is true?

A. B. C. D.

Like machines should be grouped in clusters. Machines should be grouped to produce parts of similar form. Labor is highly specialized. Manufacturing departments should be laid out according to function.

46. Which of the following are functions of a supplier scheduler? I. Material planning II. Negotiating prices with suppliers III. Releasing orders to suppliers

A. B. C. D.

I and II only I and III only II and III only I, II, and III

47. Which of the following are among the characteristics of flow control scheduling? I. Measuring movement past control points II. Knowing capacities and planned rates III. Matching work in process to specific customers

A. B. C. D.

I and II only I and III only II and III only I, II, and III

48. It material and labor are available and their costs remain constant, what is the effect on inventory dollars of a reduction in the planned and actual shop lead times on manufactured parts? A. B. C. D. Inventory dollars decrease. Inventory dollars increase. Inventory dollars do not change. The effect on inventory dollars cannot be predicted

49. When allocated on the basis of historical direct labor hours, overhead will be properly absorbed if which of the following is true?

A. B. C. D.

total volume increases total volume decreases total volume remains unchanged fixed costs decrease

50. CPM is a scheduling technique used primarily in

A. B. C. D.

job shops where many alternate routings are possible continuous process companies using flow control companies working on projects with defined beginnings and endings companies using computer-aided manufacturing (CAM) applications

Questions 51-52 refer to the following schedule of a two-operation job.

51. It can be concluded from Situation B on the schedule that

A. B. C. D.

operation 10 is not a setup operation if operation 20 is a run operation total job duration has been increased due to operation overlap the percentage of operation overlap is different from that in situation D it is impossible to overlap operation 10 with operation 20

52. Based on the schedule, accurate conclusions include which of the following? I. Increasing the number of shifts has greater impact on overall lead time than overlapping operations. II. Increasing the number of shifts has less impact on overall lead time than overlapping operations. III. The combination of overlapping operations and increasing the number of shifts will result in the shortest overall lead time. A. B. C. D. I only II only I and III only II and III only

53. The most significant factor affecting the difference between planned lead time and actual lead time for a specific order or batch in a shop is

A. B. C. D.

priority labor queues component availability

54. Which of the following are reasons for purchasing outside capacity? I. It cuts down on training costs for new employees. II. It permits increased output with no additional capital investment. III. It reduces overtime.

A. B. C. D.

I and II only I and III only II and III only I, II, and III

55. An organization treats a supplier most similarly to an inside work center when which of the following is true about external purchases? A. B. C. D. Completed components are produced. The price is the same as current standard cost. They are managed by buying capacity. They are competitively quoted.

Questions 56 and 57 are based on the following information about an employee: Hours in attendance Direct hours on production Standard hours per piece Pieces produced 10 8 1 10

56. What is the efficiency percentage for this employee?

A. B. C. D.

80% 100% 125% 133%

57. What is the utilization percentage for this employee?

A. B. C. D.

80% 100% 125% 133%

58. If the flow of received puchased parts is from receipt at the dock, to receiving/inspection, and then receipt at stores where the quantity received is entered in the ERP system, which of the following statements are true about this situation?

I. A supplier delivery performance measurement should be based on actual receipts at dock versus schedule. II. Purchase orders should be updated when all parts are received at stores. III. A resource constraint could cause parts to be received at the dock but not into the stores on schedule

A. B. C. D.

I and II only I and III only II and III only I, II, and III

59. Which of these tools is most appropriate for contingency planning?

A. B. C. D.

matrix chart process decision program chart Pareto chart continuous improvement chart

60. Employee involvement is the concept of using

A. B. C. D.

managerial employees to perform non-managerial tasks whenever they are idle employees to perform jobs outside of their assigned duties without prior consent employees' creative energy and intelligence in certain decision-making processes all of the above