Question 1.1. (TCO 3) Why would a company want to reduce the number of kanban cards they use? (Points : 5)
To implement the lean philosophy
To increase inventory
To increase WIP
To reduce inventory
Question 2.2. (TCO 6) Which of the following is true? (Points : 5)
Long lead times are typical of JIT.
WIP is high in facilities using JIT.
JIT assumes two kinds of inventories: raw materials and finished goods.
Vendor scheduling under JIT is simple.
Question 3.3. (TCO 9) Which of the following statements is correct? (Points : 5)
The first step in the TOC is to decide how to exploit a constraint.
If we break a constraint, another constraint will always appear.
Once you complete the five steps, the process is complete.
Demand for product is not a constraint.
Question 4.4. (TCO 9) Which zone usually indicates the order is farthest from the buffer? (Points : 5)
Question 5.5. (TCO 4) Operations setback charts are based on _____. (Points : 5)
each part’s queue time
each part’s lead time
each part’s move time
each part’s setup time
Question 6.6. (TCO 5) The number of periods in the basic MRP record is called the _____. (Points : 5)
Question 7.7. (TCO 12) Under JIT and time-based competition, the objective is _____. (Points : 5)
lead time reduction
decreasing material wait time
Question 8.8. (TCO 7) Which of following would you expect to be true if a company is following Toyota’s kanban system? (Points : 5)
A group of containers with the same part will have one card.
Needed parts are delivered to the requesting department.
A conveyance kanban card is needed to obtain parts.
Extra containers of product can be produced when time permits.
Question 9.9. (TCO 8) Complete the following. Under make-to-stock, _____. (Points : 5)
order promising records are not normally required
monitoring forecasts are not important
demand forecasts play a minor role in this type of scheduling environment
there is plenty of time to identify errors and institute corrective actions
Question 10.10. (TCO 10) The flawless execution needed in JIT has many important meanings. Which of the following is true? (Points : 5)
Unlike MRP, the system will not function with many defects or mistakes.
Schedule is of little importance.
Corrective actions will not be needed.
Buffer sizes are constant.
Question 1. 1. (TCO 1) What is one of the key elements of an effective PAC system? Why is this element so important? (Points : 25)
Question 2. 2. (TCO 2) Describe the desirable feedbacks PAC should have and why they are important. (Points : 25)
Question 3. 3. (TCO 3) Identify and describe in detail the four parts of lead time. (Points : 25)
Question 4. 4. (TCO 4) The capacity plan is critical to managing the flow of materials on the shop floor. Why is insufficient capacity a concern? (Points : 25)
Question 5. 5. (TCO 6) Market and manufacturing requirements determine whether you will use MRP or JIT. Discuss when it is appropriate to use MRP and JIT. (Points : 25)
Question 6. 6. (TCO 9) What changes, if any, will an organization likely need to implement in order to utilize a TOC system? Explain your answer in detail. (Points : 25)
Question 7. 7. (TCO 7) Explain the advantages and disadvantages associated with using more kanban cards versus less kanban cards under the Toyota System. (Points : 25)
Question 8. 8. (TCO 8) Many companies who once used only JIT are now trying to integrate MRP into their MPC designs. Explain why they are doing this in detail. (Points : 25)
Question 9. 9. (TCO 10) Creating JIT requires links to four other areas often called building blocks: (a) product design, (b) process design, (c) human/organizational element, and (d) manufacturing planning and control. What are five of the six activities in the area of product design? (Points : 25)
Question 10. 10. (TCO 11) Continuous improvements will often require new organizational capabilities. Identify two areas relating to information processing where continuous transformations will be needed to implement lean manufacturing. Explain why. (Points : 25)