Operation Management and TQM Review
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Questions and Answers

What is the main purpose of Heijunka in production systems?

  • To average workload volume and variety (correct)
  • To schedule projects more efficiently
  • To eliminate all variations
  • To increase production volume

    • What does the term 'master scheduling' refer to in production planning?

  • A method for maintaining inventory levels
  • The determination of quantities needed to meet demand (correct)
  • A tool for visualizing project phases
  • A system for tracking employee performance

    • What is a key feature of Lean Operations?

  • Maximizing inventory use
  • Producing a wide variety of products
  • Using minimal resources while ensuring high quality (correct)
  • Standardizing all processes

    • What does an affinity diagram primarily help with?

    <p>Organizing information from brainstorming sessions</p> Signup and view all the answers

    In project management, what does a network (precedence) diagram illustrate?

    <p>Sequential relationships of project activities</p> Signup and view all the answers

    What is defined as cumulative lead time?

    <p>The sum of lead times required for sequential phases</p> Signup and view all the answers

    What does TQM stand for, and what does it emphasize?

    <p>Total Quality Management; it involves everyone in quality improvement</p> Signup and view all the answers

    What does the projected on hand connect to in inventory management?

    <p>The expected amount at the start of a time period</p> Signup and view all the answers

    What is gross requirements in operation management?

    <p>The total expected demand for an item or raw material in a given time period.</p> Signup and view all the answers

    What does low-level coding in a bill of materials accomplish?

    <p>It restructures the bill so multiple occurrences of a component are aligned with the lowest level.</p> Signup and view all the answers

    Which of the following best defines Kanban?

    <p>A manual system for controlling movement of parts based on demand signals.</p> Signup and view all the answers

    What are the two main types of Kanbans?

    <p>Production kanban and conveyance kanban.</p> Signup and view all the answers

    What does the term 'Project Champion' refer to?

    <p>A person who promotes and supports a project</p> Signup and view all the answers

    How does the Single-Minute Exchange of Die (SMED) system benefit manufacturing?

    <p>It reduces changeover time for machines</p> Signup and view all the answers

    How does the return on quality (ROQ) approach evaluate quality investments?

    <p>By using financial return metrics like ROI to assess economic value.</p> Signup and view all the answers

    What is the primary purpose of using a Gantt chart in operations management?

    <p>To provide a visual representation for loading and scheduling.</p> Signup and view all the answers

    What is the purpose of Planning Reports in inventory management?

    <p>To forecast future material requirements</p> Signup and view all the answers

    What does the term 'Available-to-Promise (ATP) Inventory' signify?

    <p>Uncommitted inventory that can be allocated to new orders</p> Signup and view all the answers

    Which method is primarily used for planning and coordinating large projects?

    <p>Critical Path Method (CPM).</p> Signup and view all the answers

    Which process determines short-range capacity requirements in operation management?

    <p>Capacity Requirements Planning.</p> Signup and view all the answers

    What characterizes a Just-In-Time (JIT) system?

    <p>It coordinates the arrival of goods and services as needed</p> Signup and view all the answers

    In the context of project management, what does 'Activities' refer to?

    <p>Tasks that consume resources and/or time</p> Signup and view all the answers

    What is the role of a Pull System in inventory management?

    <p>To produce only what is needed based on current demand</p> Signup and view all the answers

    What does Jidoka refer to in a manufacturing context?

    <p>Quality control at the source of production</p> Signup and view all the answers

    What is the primary focus of ISO 9000 standards?

    <p>Quality management</p> Signup and view all the answers

    Which error is considered more serious in statistical process control?

    <p>Type II error</p> Signup and view all the answers

    What does the term 'Pegging' refer to in inventory management?

    <p>Identifying parent items for material requirements</p> Signup and view all the answers

    What is the purpose of a P-chart?

    <p>To monitor the proportion of defective items</p> Signup and view all the answers

    Which of the following best describes a Flow System in manufacturing?

    <p>A high-volume system following the same sequence</p> Signup and view all the answers

    What is the main characteristic of a Periodic Inventory system?

    <p>Calculates inventory at the end of a period</p> Signup and view all the answers

    What does Fail-safing in product design aim to achieve?

    <p>Prevent incorrect procedures</p> Signup and view all the answers

    Which of the following represents a key function of a Load Chart?

    <p>Shows machine loading and idle times</p> Signup and view all the answers

    What is the purpose of incorporating elements in design that make mistakes virtually impossible?

    <p>To reduce training requirements for employees</p> Signup and view all the answers

    Which of the following approaches involves constructing products according to customer specifications?

    <p>Engineer-to-Order (ETO)</p> Signup and view all the answers

    What does the term 'Heijunka' refer to within production systems?

    <p>Workload leveling</p> Signup and view all the answers

    Which of the following terms describes continuous improvement in production systems?

    <p>Kaizen</p> Signup and view all the answers

    What does 'Muda' represent in the context of lean production?

    <p>Waste and inefficiency</p> Signup and view all the answers

    Which system uses signals to indicate the need for materials or parts?

    <p>Kanban</p> Signup and view all the answers

    Which fulfillment approach involves assembling products based on pre-existing components?

    <p>Assemble-to-Order (ATO)</p> Signup and view all the answers

    What is the correct order of the components in the 5S Lean System?

    <p>Seiri, Seiso, Seiton, Seiketsu, Shitsuke</p> Signup and view all the answers

    Which method of inventory costing assumes that the first products purchased are the first to be sold?

    <p>FIFO</p> Signup and view all the answers

    What type of waste is characterized by excessive use of manufacturing resources?

    <p>Overproduction</p> Signup and view all the answers

    Which of the following is NOT a form of business organization mentioned?

    <p>Limited Liability Company</p> Signup and view all the answers

    In the steps of creating a supply chain, which step comes immediately after 'Plan'?

    <p>Source</p> Signup and view all the answers

    What is used to analyze waiting lines in inventory management?

    <p>Queuing theory</p> Signup and view all the answers

    Which type of inventory includes items that are not yet completed in the manufacturing process?

    <p>Work In Progress</p> Signup and view all the answers

    What process involves scheduling from a due date backwards?

    <p>Backward scheduling</p> Signup and view all the answers

    Which of the following is an aspect of the Lean Philosophy related to inventory?

    <p>Excess inventory is considered a waste.</p> Signup and view all the answers

    Study Notes

    Operation Management and TQM Review

    • Low-Level Coding: Restructures the bill of materials to align all occurrences of a component at the lowest level of its use.
    • Gantt Chart: A visual aid for loading and scheduling tasks.
    • CPM (Critical Path Method): A technique for planning and coordinating large projects.
    • PERT (Program Evaluation and Review Technique): Another technique used for planning and coordinating large projects.
    • Capacity Requirements Planning: A process for determining short-term capacity needs.
    • Scheduling: Establishing the timing of equipment, facilities, and human activities. Crucial in all types of organizations.
    • Johnson's Rule: Minimizes the total time required for processing a group of jobs on two machines; also minimizes idle time.
    • Muda: Waste and inefficiency in a process. Minimizing muda is key to lean philosophies.
    • Order Releases: Authorizing the planned order execution.
    • Forward Scheduling: Creating a schedule from a given point in time. Used to answer questions like "How long will the job take to complete?".
    • Backward Scheduling: Creating a schedule working backward from a due date. Useful for questions like "When is the latest the job can start?".
    • Gross Requirements: Total expected demand for an item, ignoring existing inventory.
    • Kanban: A manual system (signals) for controlling parts/material movement; two types exist (production and conveyance).
    • Return on Quality (ROQ): Approach that evaluates investments in quality improvement efforts, using metrics like Return on Investment (ROI).
    • Value Stream Mapping: Visual tool to analyze material and information flow toward a product or service.
    • Distribution Resource Planning (DRP): A method for planning orders in a supply chain.
    • Infinite Loading: Assigning jobs to work centers without considering capacity.
    • Finite Loading: Assigning jobs to centers, considering capacity and processing times.
    • Load Reports: Compare known and expected capacity requirements with available capacity.
    • Enterprise Resource Planning (ERP): Integrates standardized record keeping, enabling information sharing across departments.

    Additional Topics

    • Dependent Demand: Demand for items derived from the demand for other finished products.
    • Safety Stock: Extra inventory held to prevent stockouts.
    • Cycle Stock: Amount of inventory needed to meet expected demand.
    • Kaizen: Continuous improvement of a system.
    • Holding (carrying) Costs: Costs associated with holding an item in inventory.
    • Work Breakdown Structure (WBS): Hierarchical listing of project tasks.
    • Planning Reports: Forecasting future inventory requirements.
    • Available-to-promise (ATP): Represents uncommitted inventory, allowing marketing to give accurate delivery dates.
    • Just-In-Time (JIT): Coordinated processing system for goods and services, delivered just as they're needed.
    • Job-Shop Scheduling: Applicable to low-volume systems with a variety of requirements.
    • Heijunka: Workload leveling for low volume systems with variations in demand.
    • Channel: A server in a service system.
    • Master Scheduling: Controls information needed for all demand sources. Key in production planning and control.
    • Projects: Unique operations with a specific set of objectives within a defined timeframe.
    • Network (Precedence) Diagrams: Visual representations of project activities and their sequence.
    • Gatekeeping Screening (returns): A process of screening to prevent the acceptance of incorrect returned items & also methods for minimizing returns.
    • Flow System: High-volume systems where jobs follow a consistent sequence.
    • Flow-Shop Scheduling: Scheduling for flow systems.
    • Two key elements of managing returns: Gatekeeping Screening, Avoidance.
    • Net Requirements: Actual quantity needed for each item in each period.
    • Pegging: Identifying parent items generating material requirements.
    • P-Chart: Control chart for attribute data (proportion defective).
    • C-chart: Control chart for attribute data (number defects per unit).
    • Load Chart: Shows loading and idle time for machines or departments.
    • Fail-safing: Making processes less prone to errors by preventing incorrect procedures.
    • Single-Minute Exchange of Die (SMED): Reducing changeover time to quickly convert a machine or process.
    • Closed-Loop Supply Chain: Manufacturing controls forward and reverse product shipments.
    • Methods of Inventory Costing: FIFO (First In, First Out), LIFO (Last In, First Out), MAC (Moving Average Cost).
    • Wastes in Lean Philosophy: Inventory, Overproduction, Waiting, Transportation, Overprocessing, Inventory, Motion, Extraneous Process.

    Different Types of Inventories

    • Raw Materials
    • Work in Progress
    • Finished Goods

    Business Cycle (Flow)

    • Raw Material to Purchased Parts
    • Finished Products
    • Before a Costly Operation
    • Before an Irreversible Process
    • Before a Covering Process

    True Statements

    • Various statements on different aspects of Inventory Management and related business functions are included here.*

    Enumerations (e.g., 5S Lean System)

    • Different aspects of organizational systems like 5S and Toyota approaches to production, etc., are outlined here.*

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    Operation Management and TQM Review PDF

    Description

    This quiz focuses on key concepts in Operation Management and Total Quality Management (TQM). It covers methods such as Gantt charts, CPM, PERT, and principles like Johnson's Rule and muda. Test your knowledge of these essential tools and techniques used in effective project management and operational efficiency.

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