1- The correct answer is: D

Sourcing the same part from multiple suppliers will increase costs and decrease service to the customer. In
addition, there is a loss of volume discounts, variations in quality, poor delivery service, lack of investment by
the supplier in your business, additional required paperwork and transactions from the lack of trust and
increased travel costs to visit suppliers.

2- The correct answer is: B

With infinite loading, the load on the plant is determined by the customer due date, scheduled backward
without regard to standard capacity available to perform the work. Capacity is then reviewed for potential
improvements through overtime, subcontracting, etc.

3- The correct answer is: A

Component purchase lead time is not included in the manufacturing lead time. Manufacturing lead time would
include order preparation time, queue time, setup time, run time, etc.

4- The correct answer is: A

It is a short-range scheduling technique. The routing file contains the operation sequencing.

5- The correct answer is: C

If input is greater than output, queues and lead times will increase; if output is greater than input, they will
decrease.

6- The correct answer is: C

Backward scheduling starts with the order due date and schedules back through each operations' due date to
arrive at a start date for the order.

7- The correct answer is: C

When orders are placed on the factory without restriction, the load will be very inconsistent until the load is
leveled (smoothed). In cases where orders exceed capacity, capacity must be found or the orders must be
moved.

8- The correct answer is: B

The cycle time is the time between the completion of two units of production.

9- The correct answer is: C

0 efficiency). 100
hours needed/12.96 hours available = 7.72 or 8 days
10- The correct answer is: D

Forward scheduling begins with a start date and applies the order to each operation to calculate the completion
date. If this date is beyond the customer's need date, then some action must be taken. Forward scheduling
accounts for capacity load at the time of the order.

11- The correct answer is: B

The gateway work center is the starting work center.

12- The correct answer is: A

Capacity requirements planning or infinite loading is based on the customer due date. Operations scheduling
plans each operation to arrive at a completion date based on a finite capacity.

13- The correct answer is: B

An overloaded factory will increase lead time while output exceeding input will decrease the lead time. However,
lead time will remain constant if input = output.

14- The correct answer is: D

Manually rescheduling is the usual method for rescheduling scheduled receipts based on information MRP has
provided.

15- The correct answer is: B

Wait time would not be included as part of the operation duration, but setup time and run time would be.

16- The correct answer is: C

The more work held on the production floor, the longer the lead time will be. This happens because jobs begin to
get moved to meet customer demands. The result is that parts get moved and shuffled, reducing capacity.

17-The correct answer is: A

In the critical ratio, the date required minus the current date is divided by the time required to complete the job.
Therefore, if the demand time is greater than time required to complete, the job would be ahead.

For example:

CR = (Date required - Current date)/(Days required to complete a job) CR = 40/3 CR = 1.3

eft until the due date but only

30 days are required to complete the job.
18- The correct answer is: A

The orders for the long lead time components will be released late as visibility will not be far enough into the
future.

19- The correct answer is: A

Routings include statement I and II as well as setup and run time. They often include inspection operations,
testing, and tooling information. Statement III would be included in the bill of materials although most existing
software combines the bill of materials and the routing.

20- The correct answer is: C

21- The correct answer is: D

Prior to releasing an order to the shop floor, components must be available, the required due date should be
known, and the tooling must be available. If these requirements are not ready, then the order should not be
released. Only jobs which can be worked on should be released to the floor.

22-The correct answer is: B

Overlapped scheduling occurs when the parts begin running on subsequent operations before the job is
completed on the previous operation. The more repetitive the job is and the longer the order quantity must run,
the more often this would occur. In selecting software to do this, one must be careful, as not all software can do
this.

23- The correct answer is: C

Mixed-model scheduling allows the factory to make every model every day so the mix mirrors the sales for the
day. This is especially useful in flow manufacturing through an assembly line.

24- The correct answer is: B

Machine utilization remains high with long runs, few changeovers, and plenty of work in the queue. The only
answer which will help the machine utilization is the minimal unplanned downtime. This will allow the machine
to operate more.

25- The correct answer is: B

Line balancing refers to the fact that the time taken to perform tasks at each work station is equal or very nearly
so. This results in no bottlenecks between work stations and no buildup of work in process inventory.
26- The correct answer is: D

A constraint is any element or factor that prevents a system from achieving a higher level of performance with
respect to its goal. Constraints can be physical, as the example above is, or they can be managerial as with a
policy or procedure.

27- The correct answer is: A

Linearity is the use of resources at a level rate or maintaining a constant rate. The rate of the production in this
kind of environment is controlled by the technology in place to maintain the flow of product, and the
maintenance of the technology to avoid disruption.

28- The correct answer is: C

Therefore:

(500 * .25) + 3 =

125 + 3 = 128 hours

29- The correct answer is: C

The total manufacturing lead time is the length of time it takes to get an order through the complete
manufacturing process and be available for shipment to the customer, excluding the lower level purchasing lead
time. This would include order preparation time, queue time, setup time, run time, move time, inspection time,
and put away time. In the question, all the times would be accumulated to equal the lead time:

Run time and setup me at 101 = (3 * 200) + 60= 660

Wait me bet we en wo r k cent er = 180

Wait me aer wor k cent er 102 = 240

Move me bet we en wo r k cent er s= 30

Move me to stor age = 20

Total time in minutes = 2180

Total me in hour s (2180/ 60) = 36. 3

26- The correct answer is: B

Production activity control is concerned with the execution of the material plans. It includes the shop floor
scheduling as well as the supplier follow-up to ensure material availability.

31- The correct answer is: A

Repetitive manufacturing is defined as "a form of manufacturing where various items with similar routings are
made across the same process whenever production occurs." (APICS Dictionary) Schedules are used rather than
job orders, work-in-process inventory is backflushed very often, and the number of transactions is minimal. The
whole process of tracking the production is easier than a job shop.

32- The correct answer is: A

Setup reduction is very important as it allows manufacturing flexibility, reduces lead times, and allows for small
lots to be produced. This in turn, allows quality problems to be detected quickly.

33- The correct answer is: D

In a lean manufacturing environment, a breakdown will shut the line down due to "zero" inventories. The line is
producing units for sale with no inventory, so it is critical the line keeps producing. Additionally, useful life
extension delays an investment in equipment, thereby increasing value in the product without increasing the
fixed costs.

34-The correct answer is: D

Transaction processing, paperwork, and tracking of operations become much simpler with a JIT operation.
Because the flow of materials becomes faster and more reliable, the need for WIP tracking, for example, is
unnecessary. Purchasing can be done through vendor managed inventories whereby the parts are paid for as
they are consumed, eliminating the need for purchase orders and invoices. In the quality control area, simplified
operations eliminate the need for multiple inspections and the paperwork associated with those inspections.

35- The correct answer is: A

hours x 60 minutes). The demand for the product is 1000 units per day. Therefore, 600 minutes / the demand of
1000 = 600/1000 = .6 minutes per unit. One unit of product needs to be finished in .6 minutes or 36 seconds.

36- The correct answer is: C

In a plant where product is flowing, one can step onto the plant floor and see the flow. Work orders are
unnecessary to ensure the product is produced to meet demand. The output of the flow is the main
consideraon (1000/ day) . A vi sual or kanban m
e t hod of schedul ing to m
e et dema nd wo r ks m
o s t effic i ent ly.

37-The correct answer is: B

There is always a need for planning as kanban is really an execution system. Even with kanban in place, there
needs to be longer range planning for capacities and for material planning as lead times will often exceed the
lead time signaled in the kanban process.

38- The correct answer is: C

Setup reductions are the critical component to reducing lot size. If the kanban size is economical, reducing the
lot size may cause increased costs as the fixed cost of the setup is spread over fewer units per setup. However, if

reduce waste, there needs to be a plan for improvement.

39- The correct answer is: D

In a lean environment, material that is needed for a specific time period is stored at the point of use. Generally,
in a lean environment, more material is stored at the point of use with far less being stored as backup.

40-The correct answer is: A

In a "pull" system, the manufacturing should be completed to meet actual demand. That means the actual
orders from the customer is driving the demand for final assembly. The final assembly is driving the previous
work center, and so forth. This customer order ultimately "pulls" the manufacture of the product.

41-The correct answer is: C

According to the APICS Dictionary, cellular manufacturing is defined as, "A manufacturing process that produces
families of parts within a single line or cell of machines controlled by operators who work only within the line or
cell."

42-The correct answer is: B

Dispatch lists display the priority sequences of the manufacturing order. The "list" is printed in hard copy or
displayed on a terminal and contains information regarding the priority, location, and operation required. It is
generally produced daily in work center sequence.

43- The correct answer is: B

A focused factory has been set up to run a limited number of processes or products to allow for an efficient flow
of materials. This can be focused within a larger physical factory.

44- The correct answer is: A

Due dates are provided by MRP which maintains the priority, not MPS.

45- The correct answer is: D

The shop packet generally contains all of the above items plus others, such as engineering drawings,
manufacturing orders, and labor tickets.
46-The correct answer is: C

A job status report shows the actual progress of a job versus the completion date.

47- The correct answer is: C

The slack time rule establishes the priority on a job based on the "slack time" available. The lower the slack time,
the more critical the job. The formula in this example:

7 days * 7 hrs/day = 49

49 - 18 hours needed to complete the job = 31

48- The correct answer is: B

Robots are very good at repetitive jobs, such as welding, where humans would be bored, less accurate, and
could be injured. Where flexibility and judgement are needed, humans provide the best labor impact.

49- The correct answer is: B

Linearity refers to the use of a resource at a level rate or production at a constant rate. The rate is measured at
least daily, or more frequently.

50- The correct answer is: D

All workers in the factory should consider lead time reduction their job; however, direct labor workers can
contribute significantly to reducing lead time using the Kanban system.

51- The correct answer is: A

Subcontracting usually provides an adjustment to capacity for short and medium range planning. It is usually
used when there is a temporary capacity shortage.

52- The correct answer is: B

Essentially, the only way to relieve the bottleneck is to increase the output from the work center or decrease
the input. Increasing planned lead times will cause more work to be released to the floor.

53- The correct answer is: C

Available capacity is calculated:

54- The correct answer is: A

The work center is overloaded because the available weekly capacity is:
2 machines * l shi * 4 days * 10 hour s * .9 ul i zaon * .8 efficiency = 57.6.

The load of 72 hours is over the available capacity.

55- The correct answer is: B

The calculation of available capacity is:

s.

56- The correct answer is: B

The calculation of available capacity is:

57-The correct answer is: D

Idle time or down-time results when machines or operators are not producing product for a number of reasons
including training, setup, and maintenance.

58- The correct answer is: C

Internal setup time occurs when setups are completed while the machine is down. External setups occur while a
machine is operating.

59- The correct answer is: C

Many people believe it is only a "delivery of material as needed" system. It is a philosophy of waste elimination
and worker involvement. Additionally, work is pulled through the factory based on demand.

60- The correct answer is: C

The phrase refers to the GRADUAL (continuous improvement) reduction of lot sizes. This creates the
opportunity to eliminate obstacles as they become apparent in order to generate higher throughput.

61- The correct answer is: D

All of the above statements can improve the flow of a job shop. Reducing setup time allows multiple jobs to be
done on the same machine without the machine being down for extended periods. Defect elimination will keep
the shop from having to re-manufacture a part because there is poor quality. These changes will allow the shop
to flow the jobs from work center to work center.

62- The correct answer is: B

Just-in-Time should be implemented as a continuous improvement project. Start with a pilot and learn from the
pilot after educating the work force. A project plan to start is needed, and needs to be updated as time goes on.
However, an entire detailed project plan cannot be completed upfront, due to the changes which occur as more
is learned.

63- The correct answer is: D

Autonomation is the process whereby detection of a defect automatically shuts down a machine or line. This
concentrates the firm's resources on problem resolution - inventory can't hide the problem.

64- The correct answer is: B

An andon is a type of signal system which provides visibility to the floor conditions. Generally, red (stop), green
(running), and yellow (needs attention), indicates production line conditions.

65- The correct answer is: D

All of the answers add no value to the customer and should be eliminated. This can be done through the use of
information technology.

66- The correct answer is: A

The term poka-yoke refers to a technique of mistake proofing a process. For example, having parts assembled in
a certain way so they can only be finished with all the parts included. A setup may be poka-yoked in such a way
so the fixture can only go in a certain way without any manipulation.

67- The correct answer is: D

Backflushing occurs when the product is received into finished goods inventory or at a count point in the
operation. The components are deducted from inventory for the finished goods quantity times the bill of
materials for the product.

68-The correct answer is: C

Appraisal costs include the costs of testing and inspecting - both non-value adding.

69-The correct answer is: B

In the first three periods, output exceeded input by 60 hours; 35 in Period 1, -5 in Period 2, and 30 in Period 3.

70- The correct answer is: D

As long as the input does not exceed or equal the planned output, the backlog will be reduced. The lower the
input, the greater the backlog will be reduced.

71-The correct answer is: B

By definition, quality is the conformance to requirements. The other answers could be measurements of the
conformance.
72-The correct answer is: C

To enable or give authority to people empowers them to be able to make improvements in their work place.
This authority generates dramatic improvements.

73- The correct answer is: B

Flowcharts are used to analyze any process whether it is material or information related. Scatter diagrams are
also used to identify correlation's between data points from a process. GANTT charts are used for scheduling to
measure actual performance against the planned schedule.

74- The correct answer is: A

A cause-and-effect diagram (also known as a fishbone diagram) is a tool for analyzing process problems. The
diagram identifies the causes and subcauses leading to a symptom (or problem).

75- The correct answer is: C

A customer's audit team may include a quality engineer, manufacturing engineer, buyer, materials manager, or
design engineer. They will generally not include sales and/or marketing.