Deck 10: Lean Systems and Six-Sigma Quality

Question 1

Outcomes of implementing a lean philosophy in an organization include:

A) Cost reductions
B) Improved customer satisfaction
C) Improved quality
D) All of the above
E) None of the above

Answer 1

D

Question 2

ISO 9000 quality standards were developed in response to:

A) Increasing international trade
B) Excessive product failures
C) Government intervention
D) The need for universal standards
E) a and d

Answer 2

E

Question 3

______ is a management approach that seeks to utilize resources as efficiently as possible.

A) Lean
B) Sales and Operations Planning
C) Six Sigma
D) CPFR
E) a and c

Answer 3

E

Question 4

in Statistical Quality Control (SQC), ________ determines whether a batch of goods should be accepted or rejected:

A) Descriptive statistics
B) Statistical Process Control (SPC)
C) Acceptance sampling
D) TQM
E) None of the above

Question 5

In a lean philosophy, all process are driven by the goal to:

A) Reduce costs
B) Develop new products
C) Improve profits
D) Serve the customer
E) b and c

Question 6

Of the three elements of lean, lean production focuses on:

A) Just-in-time systems
B) Pull production systems
C) Operations systems
D) Delivery systems
E) All of the above

Question 7

Costs of quality incurred when testing and evaluating products is known as:

A) Prevention costs
B) Appraisal costs
C) Internal failure costs
D) External failure costs
E) None of the above

Question 8

Small lot size production must be balanced with the costs of ___________:

A) Inventory
B) Labor
C) Setup time
D) Variation
E) Transportation

Question 9

The tenet that waste can only be eliminated when it can be clearly identified is:

A) Simplicity
B) Visibility
C) Flexibility
D) Continuous improvement
E) None of the above

Question 10

Costs of quality incurred when a customer returns a defective product is known as:

A) Prevention costs
B) Appraisal costs
C) Internal failure costs
D) External failure costs
E) None of the above

Question 11

In a ________ production system, products are made in anticipation of demand.

A) Push
B) Pull
C) Stable
D) Variable
E) Lean

Question 12

Lean production utilizes a __________ production system:

A) Push
B) Quality
C) Pull
D) Complex
E) a and d

Question 13

The mean, standard deviation, and range are examples of:

A) Descriptive statistics
B) SPC
C) Acceptance sampling
D) TQM
E) None of the above

Question 14

The ________ quality tool is used to identify causes of a problem:

A) Fishbone diagram
B) Flowchart
C) Checklist
D) Control chart
E) Scatter diagram

Question 15

Lean emphasizes __________ solutions to supply chain problems:

A) Complex
B) Expensive
C) Simple
D) Managing
E) Functional

Question 16

One of the most simple, yet highly effective quality tools is a:

A) Fishbone diagram
B) Flowchart
C) Checklist
D) Control chart
E) Scatter diagram

Question 17

Core tenets of the lean philosophy include:

A) Complexity
B) Waste reduction
C) Functional view
D) Statistical process control
E) a and b

Question 18

_________ is a quality tool that shows the relationship to two variables:

A) Fishbone diagram
B) Flowchart
C) Checklist
D) Control chart
E) Scatter diagram

Question 19

The role of management in an organization that practices a lean philosophy is:

A) Disciplining employee
B) Enforcing TQM guidelines
C) Ensuring quality processes are followed
D) Facilitating cultural change
E) None of the above

Question 20

Meeting and exceeding customer expectations is the definition of:

A) Operations
B) Quality
C) Marketing
D) Kaizan
E) a and b

Question 21

Evaluating a process to determine if it meets established quality standards is known as:

A) SPC
B) Value stream mapping
C) Pareto analysis
D) Sales and operations planning
E) Process capability

Question 22

Eliminating waste is at the core of the lean philosophy, which includes anything that does not add value to the customer.

Question 23

Two fundamental aspects of Six Sigma methodology include:

A) People and processes
B) Data and charts
C) SQC and SPC
D) Technical tools and people
E) None of the above

Question 24

The tool used to measure a process whose characteristics consist of attributes is knows as:

A) t-chart
B) Histogram
C) p-chart
D) Checklist
E) None of the above

Question 25

Lean production utilizes a "push" production system.

Question 26

The 'lean production' element of lean is responsible for a company's operations and delivery system.

Question 27

A benefit of lean implementation is increased customer service.

Question 28

____ ____is a critical tool needed for supply chain partners to achieve the benefits of Six Sigma.

A) Pull production systems
B) Value stream mapping
C) SPC
D) Information technology
E) Kaizan

Question 29

While beneficial to an organization, lean solutions are typically complex and expensive.

Question 30

Lean is primarily a production/manufacturing process.

Question 31

In the lean philosophy, all processes are driven by the overriding goal to reduce costs.

Question 32

Variation that can be identified and changed is known as:

A) Random
B) Assignable
C) Common
D) Visible
E) Capable

Question 33

Once a process is 'in control,' the tool used to continuously monitor the process is a:

A) Pareto diagram
B) Histogram
C) Flowchart
D) Control chart
E) None of the above

Question 34

A valuable tool in Six Sigma supply chains used to identify system improvements is knows as:

A) Value stream mapping
B) Histogram
C) Pareto analysis
D) Flowcharts
E) Checklists

Question 35

The lean management approach seeks to utilize resources as efficiently as possible.

Question 36

The operations function can be impacted by Six Sigma in the following ways:

A) Pull production systems
B) Cycle time reductions
C) Increased inventory turns
D) All of the above
E) None of the above

Question 37

Utilizing multiple machines for different functions is an example of lean flexibility.

Question 38

A range of acceptable quality that has been tested and established is known as:

A) Value stream mapping
B) Histogram
C) Product specifications
D) Tolerances
E) c and d

Question 39

An emphasis on continuous improvement is known as kaizen

Question 40

A Six Sigma philosophy includes the following:

A) Zero defects
B) Rigorous measurement
C) Involves every aspect of the organization
D) Extensive training
E) All of the above

Question 41

Scrap and rework are examples of appraisal costs of quality.

Question 42

A pareto analysis is a quality tool used to prioritize problems.

Question 43

The lean philosophy emphasizes using multiple supplier sources to reduce risk.

Question 44

"Leveling" the production schedule reduces variation in the production process.

Question 45

The mean and standard deviation are tools used to describe characteristics of a distribution.

Question 46

In order to effectively achieve small lot production, companies must reduce production time.

Question 47

Cycle time and inventory are key aspects of operations that can be improved with Six Sigma methodologies.

Question 48

Variation that can be identified and managed is knows as common variation.

Question 49

A key requirement of lean implementation is that workers are trained to have cross-functional skill sets.

Question 50

Respect for people is a key element of lean and typically only applies to the internal operations of a company.

Question 51

In "push" production systems, goods are produced based on a forecast.

Question 52

Lean organizations typically have strict hierarchical management structures.

Question 53

Small lot productions decrease flexibility because of the risk of insufficient stock on hand.

Question 54

The goal of Six Sigma is to achieve "zero defects."

Question 55

Visual signals used in lean production systems are known as kanbans.

Question 56

Meeting and exceeding customer expectations is today's definition of quality.

Question 57

The primary role of management in a lean organization is to ensure quality processes are strictly followed.

Question 58

If a process is not 'capable' then quality standards are useless.

Question 59

Total Quality Management (TQM) allows for an acceptable number of defects in a product or process.

Question 60

Processes are known to be in a state of control when data points exceed the normal range of variation.

Question 61

Describe the two fundamental aspects of Six Sigma methodology.

Question 62

Describe the five step plan around which a Six Sigma approach is organized.

Question 63

Briefly describe the steps involved in developing a lean Six Sigma supply chain.