DSCI Test 2

+Students have to change buildings between classes, which often involves walks of 5 minutes or more. Walking from one building to another is:
+Waste
+Non-value added time
+Value added time
+None of above
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+Students have to change buildings between classes, which often involves walks of 5 minutes or more. Walking from one building to another is:
+Waste
+Non-value added time
+Value added time
+None of above
Non-value added time
+In a service operation, we can compute the value-added time by simply looking at the labor content.

True/False
False
(The labor content might include processing times that are not value add to the customer.)
+If customers want to have 1000 units over 10 days, one should aim at producing 100 units per day instead of doing 111 units per day in the beginning and then having a little safety buffer at the end.

True/False
True
+If the demand rate increases, the takt time
+Increases
+Decreases
Decreases
What is the takt time equation?
TT = 1 / Demand Rate
+A new backpack that has a zipper which is broken due to a supplier problem is indicative of a quality problem resulting from assignable cause variations.

True/False
True
+A process capability index of 2 means that the upper and lower specification limits of the process are six standard deviations above and below the mean respectively.

True/False
True
+C&A is making steel rods with an average diameter of 1 mm. The process has a standard deviation of 0.2 mm. The upper and lower specification limits are 1.2 mm and 0.8 mm respectively. What is C&A's process capability index?
Process capability index = (1.2 − 0.8)/(6 × 0.2) = 0.333.

Cp = (USL - LSL)/(6*Sigma)
+A company making tires for bikes is concerned about the exact width of its cyclocross tires. The company has a lower specification limit of 22.9 mm and an upper specification limit of 23.2 mm. The standard deviation is 0.17 mm and the mean is 23.1 mm. What is the process capability index for the process?
Cp =USL − LSL/6 sigma=23.2 − 22.9/ 6*0.17=0.2941
+For 107 consecutive days, a process engineer has measured the temperature of champagne bottles as they are made ready for serving. Each day, she took a sample of 10 bottles. The average across all 1,070 bottles (107 days, 10 bottles per day) was 43 degrees Fahrenheit. The standard deviation across all bottles was 1.1 degree Fahrenheit. When constructing an X-bar chart, what would be the center line?
The center line would be given by the average across all 1070 bottles, i.e., it would be 43 degrees.
If the takt time is shorter than the cycle time, the process needs to run faster. True/FalseTrueIt is possible to increase process capacity by balancing a process. True/FalseTrueTakt time matches cycle time if supply matches demand. True/FalseTrueLine balancing can only be applied to activities with a fixed sequence. True/FalseFalseIt takes a lawyer 120 minutes to serve one customer. Demand is 2 customers per 8-hour day. The lawyer has a wage rate of $200 per hour. What is the cost of direct labor for the lawyer expressed in $ per customer? What is the labor utilization of the lawyer?Flow rate = ¼ customers per hour. Capacity is ½ customer per hour. Direct Labor cost is (8 hours × $200 per hour)/2 customers = $800 per customer. Labor utilization = Flow rate / Capacity = ¼ / ½ = 0.5uConsider a process consisting of three resources. Assume there exists unlimited demand for the product, and that all activities are always performed in the following sequence. uResource 1 has a processing time of 6 minutes per unit. uResource 2 has a processing time of 3 minutes per unit. uResource 3 has a processing time of 5 minutes per unit. All three resources are staffed by one worker and each worker gets paid $10 per hour. a. What is the cost of direct labor? b. What is the labor content? c. What is the average labor utilization?a. Resource 1 is the bottleneck center at 6 minutes per unit. The Direct Labor cost is (6 minutes per resource × 3 resource centers/60 minutes per hour) × $10 per hour = $3.00 b. Labor content = 6 minutes Resource 1 + 3 minutes Resource 2 + 5 minutes Resource 3 = 14 minutes c. Labor Utilization = 14 labor content/18 capacity = 77.78%Consider a process consisting of three resources. Assume there exists unlimited demand for the product, and that all activities are always performed in the following sequence. Resource 1 has a processing time of 5 minutes per unit. Resource 2 has a processing time of 2 minutes per unit. Resource 3 has a processing time of 4 minutes per unit. All three resources are staffed by one worker and each worker gets paid $11 per hour. a)Assume the demand rate is 24 units per hour. What is the takt time? b)Assume the demand rate is 24 units per hour. What is the target manpower?a) Takt Time = 1/Demand rate = 1/(24 customers/60 minutes) = 2.50 minutes b) The target manpower = 11 Labor content/2.50 minutes Takt time = 4.40Clients are served in a process with two resources. The processing times for the resources are 1.4 and 2 hours. What is the labor content (in hours)?The labor content of each unit is the sum of the processing times. 1.4 + 2 = 3.40 hours.If __________ is the constraint, we should __________ the staffing level to lower capacity. a)demand, lower b)demand, raise c)capacity, raise d)capacity, lowerAA possible drawback of having each employee specialize in one or several activities in serving customers at a coffee shop is __________. a) increased idle time b) higher direct labor costs c) increased equipment replication d) increased processing timeAStudents have to change buildings between classes, which often involves walks of 5 minutes or more. Walking from one building to another is Waste Non-Value added time Value added timeNon-value added timeWhich of the following strategies or techniques would reduce inventory in the operation? Control charts Jidoka Poka-yoke HeijunkaHeijunkaWhich of the following strategies or techniques would use the principle of jidoka to increase quality? Reducing changeover time Ikko-nagashi Andon KanbanAndonAn example of a lean operation is to have workers circulating in a store, waiting for customers to check out on mobile payment units. True/FalseFalseA worker moving inventory from one machine to another is considered non-value-added work. True/FalseTrueThe 4Ps of the TPS are place, promotion, people, and profit. True/FalseFalseWhat are the 4P's of TPS?philosophy, processes, people, and problem solvingWhich of the following is an example of wasted flow time? A long waiting time at a checkout Idle time of a cashier Merchandise returned to a store Ringing up sales at a registerA long waiting time at a checkoutWhich of the following terms is interchangeable with "lean"? Value adding Toyota Production System Green No waitingToyota Production SystemA machine is available 10 hours a day. Each part takes 90 minutes to fabricate and 10 minutes to setup. 10% of the parts made are defective and must go through the machine again to be reworked, during which both setup and fabrication have to be performed again. The machine is idle for any unused time. On average, 5 good parts are made each day. What is the overall equipment effectiveness of the machine?0.75 (Total time available = 10 × 60 = 600 minutes. Value added time = 90 × 5 = 450 minutes. OEE = 450 / 600 = 0.75)Which of the following is NOT one of the seven sources of waste? Inventory Overproduction Processing MovementProcessingA lean operation strives to achieve a reduction of __________ and __________ simultaneously. demand in capacity, available time demand in capacity, flow time waste in capacity, flow time waste in capacity, available timewaste in capacity, flow timeWhich of the following is NOT one the 4Ps of Toyota production system? People Profit Processes PhilosophyProfithe Toyota Production System is often depicted as a house. The two pillars of the TPS are __________ and ___________. waste reduction, just-in-time flow process improvement, just-in-time flow waste reduction, built-in quality built-in quality, just-in-time flowbuilt-in quality, just-in-time flowmeans to produce in the amounts needed, when needed, and where needed using a single unit flow. Just-in-time Built-in quality Process improvement Stable environmentJust-in-timeIn a pull system, an information flow of external demand is moving __________ and the physical flow of the flow units is moving __________. downstream, upstream upstream, downstream upstream, upstream downstream, downstreamupstream, downstreamFollowing the announcement of a major quality problem, the share price of a company falls substantially. This decrease is a result of assignable cause variation. True/FalseTrueIf a process has a six-sigma capability, what is the process capability index? 1 2 6 122Which of the following definitions describes a robust process? A) A process is robust if it can tolerate variation in input and environmental variables without producing a defect. B) A process is robust if it has a lot of automation built in. C) A process is robust if it uses control charts. D) A process is robust if its process capability index is greater than 1.AA company making tires for bikes is concerned about the exact width of its cyclocross tires. The company has a lower specification limit of 22.6 mm and an upper specification limit of 23.3 mm. The standard deviation is 0.18 mm and the mean is 22.9 mm. What's the process capability index?0.6481 (UCL - LCL)/6*SigmaFor 135 consecutive days, a process engineer has measured the temperature of champagne bottles as they are made ready for serving. Each day, she took a sample of 8 bottles. The average across all 1,080 bottles (135 days, 8 bottles per day) was 42 degrees Fahrenheit. The standard deviation across all bottles was 1.5 degree Fahrenheit. What would be the center line in an x-bar chart?42 degreesFor 107 consecutive days, a process engineer has measured the temperature of champagne bottles as they are made ready for serving. Each day, she took a sample of 9 bottles. The average across all 963 bottles (107 days, 9 bottles per day) was 60 degrees Fahrenheit. The standard deviation across all bottles was 1.4 degree. When constructing an X-bar chart, what would be the upper control limit?Estimated standard deviation (X-bar)= Standard deviation of all parts / sqrt(n) = 1.4 / sqrt(9) = 0.46667 We then find the upper control limit as: UCL = X¯¯X¯ + 3 × ESD( X¯¯¯X¯ ) = 60 + 3 × 0.46667 = 61.40000You are working in a small, student-run company that sends out merchandise with university branding to alumni around the world. Every day, you take a sample of 50 shipments that are ready to be shipped to the alumni and inspect them for correctness. Across all days, the average percentage of incorrect shipments is 5 percent. What would be the upper control limit for a p-chart?0.142An X bar chart is used to track a process with binary outcome variables. True/FalseFalseA P bar chart is used to track a process with binary outcome variables. True/FalseTrueC&A runs a pizza restaurant. Which of the following is an output variable for C&A? The amount of cheese purchased from the supplier The weather condition The delivery time of the pizza The number of employees working for C&AThe delivery time of the pizzaA process is replicated in another country where wages are 50 percent lower. Staffing and processing times are identical. What would be the effect on the costs of direct labor? Costs of direct labor would be 50 percent lower. Costs of direct labor would be the same. Costs of direct labor would be 50 percent higher. Cannot determine from the given information.Costs of DL would be 50 percent lowerYou and three of your friends run a car wash for a fund-raiser. Between interior and exterior cleaning, you spend about 40 minutes per vehicle. You are so successful that the next day you invite four more friends to help. How does this impact the labor content? The labor content goes up. The labor content stays the same. The labor content goes down. Cannot determine from the given information.Labor content stays the sameA group of workers works really hard. In fact, they work so hard that one of them claims to have an average labor utilization of 120 percent. Is that possible?NoThe bottleneck has the least idle time True/FalseTrueWhich of the following statements about takt time and cycle time is true? Takt time only depends on demand, not capacity. Cycle time does depend on capacity. Takt time only depends on capacity, not demand. Cycle time depends on demand. Takt time and cycle time only depend on capacity. Takt time and cycle time only depend on demand.Takt time only depends on demand, not capacity. Cycle time does depend on capacity.If the takt time is shorter than the cycle time, the process needs to run faster. True/FalseTrueHow does the takt time change as the demand rate increases? The takt time increases. The takt time stays the same. The takt time decreases. Cannot determine from the given information.The takt time decreasesHow does the target manpower change as the demand rate increases? The target manpower increases. The target manpower stays the same. The target manpower decreases. Cannot determine from the given information.The target manpower increasesBalancing a process with a fixed sequence of activities will achieve a higher average labor utilization than balancing a process with no fixed sequence of activities. True/FalseFalseSpecialization increases the costs of labor because specialists will command a higher wage rate. True/FalseFalseSpecialization typically lead to a higher average labor utilization. True/FalseFalseIf __________ is the constraint, we should __________ the staffing level to lower capacity. demand, lower demand, raise capacity, raise capacity, lowerdemand, lowerC&A operates three eight-hour shifts to produce 600 gallons of a chemical per day. It requires 12 minutes of labor to produce a gallon of the chemical. What is C&A's takt time in minutes per gallon, and what is the target manpower?Takt time = Available time/Required quantity = 3 × 8 hours/600 gallons = 0.04 hours per gallon = 2.4 minutes per gallon. Target manpower = Labor content/Takt time = 12 minutes per gallon/2.4 minutes per gallon = 5.Which of the following statements about takt time is FALSE? Takt time is the ratio between the available time and the required production quantity. Takt time is dependent on the required quantity of output. Incorrect Takt time tells us how much time actually elapses between completing two consecutive units. Takt time tells us how much time should elapse between completing two consecutive units.Takt time tells us how much time actually elapses between completing two consecutive units.Which of the following statements about target manpower is TRUE? Target manpower gives the maximum number of resources required to meet demand. The only way to compute target manpower is through cycle time. The target manpower calculation assumes that all resources are utilized at 100%. The target manpower calculation accounts for idle time in the process.The target manpower calculation assumes that all resources are utilized at 100%.Which of the following statements about takt time and cycle time is TRUE? If takt time is longer than cycle time, target manpower will be higher than current staff level. If takt time is longer than cycle time, target manpower will be lower than current staff level. Supply matches demand when takt time is shorter than cycle time. Supply is less than demand when takt time is equal to cycle time.If takt time is longer than cycle time, target manpower will be lower than current staff level.