Page 1
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)
Green zone
Red zone
Yellow zone
Dead zone
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)
new horizon
planning
horizon
time horizon
time bucket
Question 7.7. (TCO 12) Under JIT and time-based competition,
the objective is _____. (Points : 5)
WIP reduction
lead time
reduction
decreasing
material wait time
material
velocity
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.
Page 2
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)
