8.1 Goldratt’s theory of constraints deals with money in relationship to 3 fundamental measurements for evaluating systems. Which of the following measures align with their monetary equivalents?
b. Inventory is money struck inside
8.2 What is the main effect of temperature in this experiment
difference= 70.75-52.75 = 18
8.3 Certain six sigma improvement efforts have resulted in the need to replace the existing measurement system and others have not. What could be the reason for staying with an existing system?
d. An improvement isn’t necessary
8.4 The floor of a small shop looks dirty, disorganized, and messy. The manager tells you that this is ok, they will perform their annual 5S day as soon as they finish a current large order. You tell the manager this is not really 5S because:
a. 5S is systematic and formal
8.5 One would say that continuous flow manufacturing:
d. Provides mechanisms to solve other production problems
8.6 In conducting a fractional factorial it is known that factors A,B,C,D and E are independent of each other, but factors F and G may not be independent. A small sub-experiment revealed a high correlation between factors F & G. What is the name of this condition?
8.7 How does poka-yoke respond to human error?
d. By catching human error before it becomes a defect
8.8 A Latin square design is an experimental design which:
a. Cannot be used when estimation of the interaction effects is desired
8.9 Which of the following is considered the sixth “S”?
8.10 Id the lean enterprise technique in which the videotaping of a segment of the operation is helpful:
8.11 The theory of constraints concentrates mainly on:
d. Removing process bottlenecks
8.12 Id the improvement methodology which would be most effective in validating the outcome of an improvement activity when only qualitative data is involved.
c. Pareto diagram reanalysis
8.13 If an experiment has an alias, one would say that the two factors effects are:
8.14 A poka-yoke device detects an error and stops the process. What should be the operator do next?
a. Find the root cause of the problem and carry out corrective action
8.15 What is the major reason that the Japanese place such a high emphasis on housekeeping items in the 5S approach?
a. They figure that workplace organization and manufacturing are inseparable
8.16 Id the most difficult limitation in achieving continuous flow?
b. Untrained employees
8.17 Ideally, what sequence of experimentation should one use to optimize the response of a process
b. Use screening first and then response surface techniques
8.18 SMED helps a company create a competitive edge by allowing the company to:
a. Complete production setups quickly
8.19 The smallest run number possible in order to examine the main effect of 22 factors at 2 levels is:
8.20 Which of the following principles of 5S in the Americanized version is called seiton in the Japanese version?
a. Sorting of
8.21 When performing “1 experiment with 5 repetitions,” what are the 6 experiments called?
8.22 Which of the following techniques independent of the visual factory concept?
8.23 Which of the following is a defect elimination and detection technique?
c. Source inspection and operator self check
8.24 A 2 level, 5 factor experiment is being conducted to optimize the reliability of an electronic control module. A half replicate of the standard full factorial experiment is proposed. The number of treatment combinations will be:
8.25 What does the Japanese concept of poka-yoke mean?
c. Mistake proofing
8.26 Red tagging is used during which 5S stage?
8.27 The main objection to designed experimentation in an industrial environment is:
b. Getting excessive scrap as a result of choosing factor levels that are too extreme
8.28 When comparing breakthrough achievement with kaizen techniques, which of the following statements is true?
d. Kaizen techniques are more easily applied at the floor level
8.29 Which of the following is an internal setup operation?
b. Changing dies
8.30 The main difference between traditional kaizen blitz approach is:
b. The pace of change effort
8.31 What is considered an ideal batch size in a continuous flow operation?
c. One piece is considered ideal
8.32 An experiment yielding the following equation:
What can be said about the response surface?
b. It contains a cuve component
8.33 In the SMED system what is the real meaning of the single minute concept?
c. The dies will be exchanged in less than 10 minutes
8.34 Why is deep cleaning (shine) performed until the third step of 5S and not before?
c. It makes sense to perform cleaning after sorting and straightening the work place
8.35 EVOP should be used:
d. When a process is producing satisfactory material
8.36 Id the tool that would generate an experimental equation after a DOE has been completed.
c. Computer software
8.37 In CFM, the time per operation is based on:
a. The takt time
8.38 Just-in-time (JIT) is collectively characterized by:
a. Producing and delivering the right items
8.39 Which of the following tools would be of minimal value when assessing the results of an improvement team’s activities?
d. A brainstorming session
8.40 Kanban concepts include which of the following
8.41 In a production factory, that utilizes the pull system, which of the following may be achieved?
b. Reduced in -process inventory
8.42 What is the resolution of a Plackett-Burman design with n runs and n-1 factors?
d. Resolution lll
8.43 A concept that includes lean enterprise but goes a step further by integrating all aspects of product cycle time is called:
8.44 In every experiment there is experimental error. Which of the following statements is true?
a. It is due to a lack of material uniformity and to inherent experimental variability
8.45 Which of the following 5S stages is primarily the responsibility of top management?
8.46 Kaizen techniques:
b. Should be planned properly
8.47 Experiments can have many different objectives. Which of the following would be included in surface response objectives?
c. Central composite of Box-Behnken designs
8.48 The term kaizen blitz entails:
d. Rapid workplace change on a project basis
8.49 When studying a combination of qualitative and quantitative factors in a 2^5 full factorial design, a member of a lean six sigma group recommends removing the qualitative factors in order to study only numerical combinations of effects. What id your reaction to this request?
d. You keep both factors and calculate the effects of both factors
8.50 One would say that the kanban method would be most closely associated with:
d. The control of material flow
8.51 Which of the following is a TOC principle?
d. The control of material flow
8.52 What is the technique used to control the release of raw material from a constraint to the downstream equipment?
8.53 An incomplete experimental block design may be especially suitable when:
c. It may not be possible to apply all treatments in every block
8.54 Which of the following operations would benefit most from a kanban system application?
c. Repetitive production plants
8.55 Ergonomics reduce injuries and lost production. Which of the following is a sound ergonomic principle in the workplace?
c. Redesigning tools to reduce stress
8.56 Which is the main activity necessary to keep a 5S program working?
c. 5S audits
8.57 Why would lean six sigma activities prompt a reanalysis of measuring systems?
b. Variability may be reduced, requiring more precise measurements
8.58 The reduction of lead times is one of the main objective of kanban. Which of the following is the other main objective?
d. To control the factory
8.59 There is strong interactive between two variables. This means that:
a. An interaction occurs when the effect of one input factor on the output depends upon the level of another input factor
8.60 Which of the following maintains and improves working standards by small gradual evolutionary improvements.