Engineering homework help.

Question 1

What defines a problem in the 8 step problem solving method?

	A.	Team members
	B.	Leadership
	C.	A performance gap
	D.	Defects

Look at the image below and record the Actual Cycle Time.
ACT = Manual (Automatic) Time + Walk (Transport) Time + Wait Time
= (85+105+360)s+(35+10)s = 595 s
 

Question 3

In step 2 of the 8 step problem solving method, it is important to classify and _______ the problem.

	A.	quantify
	B.	solve
	C.	organize and analyze
	D.	breakdown

Question 4

You are a Manufacturing Engineer and received notice that the customer has increased their order to 390 pieces/shift.  You are working one 8 hour shift with a 30 minute lunch and two 10 minute breaks.  What is the total TAKT time needed, in seconds, for the shift?
TAKT time =  total allowable time to work / customer demand
 
total allowable time to work = 8h shift – 30 min lunch – 2*10 min breaks = 480 min – 30 min – 20 min = 430 min = 430*60 = 25800 s
customer demand  =  390 pieces/shift
TAKT time  = 25800 / 390 = 66.15 s
 

Question 5

What defines the gap?

	A.	The difference between the current situation and zero defects
	B.	The difference between the best production run and the worst production run
	C.	The difference between the current situation and the standard
	D.	The difference between the standard work and the ultimate goal

Question 6

What is Toyota s approach to computers?

		a. They are tools, but not a replacement for people
		b. They can take the jobs of humans and save money
		c. They are terrible
		d. They are the best thing to ever happen to production

Question 7

Kanban provides all of the following, except

		a. improved predictability
		b. less visibility onto quality and process problems
		c. shortens the lead time
		d. improved due date performance

Question 8

Which of these best relates the meaning of heijunka?

		a. The leveling of ground during a landscaping project.
		b. Work injury pertaining to excessive repetitious motions.
		c. Fines issued when a company doesn t meet deadlines.
		d. Leveling of production by both volume and product mix.

Question 9

The basis for continuous improvement and quality is

		a. Coerciveness.
		b. Enabling.
		c. Red tape.
		d. Standardization.

Question 10

What is an A3 report?

		a. A useless piece of paper
		b. An 11×17 sheet of paper that gives a large report on a budget, or problem, etc.
		c. A report that is just a bunch of pictures and hard to read
		d. A tool for the production workers

 

Question 11

What is so important about the pull system?

		a. Limits number of products made.
		b. Saves money
		c. Keeps the process quick.
		d. All the above.

 

Question 12

What is the signal called that alerts team members when a problem arises?

		a. Andon
		b. Andoff
		c. Jidoka
		d. TPS

Question 13

Who does Toyota empower to make improvements

		a. The Team Members
		b. Managers
		c. Customers
		d. Suppliers

Question 14

A kanban card is usd to signal that:

		a. a machine has broken down
		b. a worker is falling behind and needs help
		c. a defect has occurred
		d. parts are needed

Question 15

What does jidoka mean?

		a. leveling out the workload
		b. eliminating waste
		c. stopping the process to build in quality
		d. continuous flow

 

Question 16

The Toyota Way is not about managing inventory; it is about ___________ it.

		a. Eliminating
		b. Cleaning
		c. Storing
		d. Collecting

Question 17

When is it better to implement new machinery?

		a. When it adds value to the process
		b. When it can produce faster
		c. When it is easier to use
		d. When it will save money in the long run

 

Question 18

Why is empowering the employees in a company important?

		a. Because employees are what drives the company
		b. It doesn’t create a bureaucracy in the company
		c. It keeps morale up
		d. All of the above

Question 19

What is Poka-Yoka?

		a. A means of signaling for more product
		b. A device that creates holes in metal
		c. An error proofing system
		d. A manufacturing process used to correct problems

Question 20

How does countermeasures help error proofing?

		a. It doesn t because it causes more problems.
		b. It finds the source of the problem and provides solutions to stop it
		c. Both a and b
		d. None of these

Question 21

One way Toyota measures processes is through

		a. Standardization
		b. Heijunka
		c. Global performance measures
		d. Operational performance measures

Question 22

Using small lot sizes reduces the flexibilty of a system.
True
False
 

Question 23

The 5S program (in order) is?

		a. sort, straighten, shine, standardize, and sustain
		b. Standardize, shine, straighten, sort, sustain
		c. Shine, Sort, Straighten, Standardize, Sustain
		d. Sustain, standardize, shine, sort, straighten

Question 24

A level process offers which of the following?

		a. flexibility for the customer
		b. reduced risk of unsold goods
		c. balanced use of labor and machines
		d. all of the above

Question 25

Which is one of the four key statistical tools used within Toyota, referenced in chapter 11?

		a. Go and see.
		b. Go on lunch break.
		c. Ask a team manager.
		d. Communicate with co-workers.

Question 26

Inventory is considered a waste in a lean system
True
False

Question 27

The best countermeasure for quality problems is

		a. Standardization
		b. Heijunka
		c. Muda
		d. Muli

Question 28

Why should you level production?

		a. To make more money
		b. To make up lost time
		c. To prevent a fluctuation in work load
		d. So some work is easier than others

Question 29

What does Heijunka mean?

		a. Waste
		b. Leveling
		c. Reduction
		d. Time

Question 30

What is the first lesson of management?

		a. Putting The Customer First
		b. Putting yourself first
		c. Putting your employees first
		d. Putting money first

Question 31

Lowering inventory levels is a tactic to expose quality problems in a lean system.
 True
 False
 

Question 32

The term that relates to matching the output rate with customer demand in a JIT system is:

		a. fill rate
		b. takt time
		c. closed-loop JIT
		d. single-minute exchange of die

Question 33

What does Hansei mean?

		Redundancy
		Reuse
		Research
		Reflection

Question 34

A KPI that is focused on activities which precede the results is called a process KPI.
True
False

Question 35

How do you become a learning organization?

		a. Hansei and Genchi
		b. Genchi and Genbutsu
		c. Kaizen and Taiichi
		d. Kaizen and Hansei

Question 36

A KPI that is focused on the outcome of activity against a specific target is called a Process KPI.  An example would be “the cake tastes good”.
True
False
 

Question 37

This allows you to see the normal state and quickly see a deviation from the standard.

		a. Standardization
		b. Visual Management
		c. Jidoka
		d. Andon Light
		e. Visual Control

Question 38

What is Nemawashi?

		a. Gaining consensus on all decisions to consider all options
		b. Talking to other people
		c. Agreeing with what everyone says
		d. Your boss has the final word in all decisions

Question 39

What size paper does Toyota use to arrive at decisions?

		a. A1
		b. A2
		c. A3
		d. A4

Question 40

What is Muri?

		a. Overabundance of people or equipment
		b. Oversimplifying people or equipment
		c. Overturning people or equipment
		d. Overburdening people or equipment

Question 41

This is an example of an inventory push system:

		a. Internet service where you buy dairy products.
		b. Yard Sale.
		c. Flea Market.
		d. Second Hand Store such as Goodwill .

Question 42

According to Toyota, what are computer systems good for?

		a. They are accurate with numbers and keeping track of progress
		b. They can do the same job as a human but better
		c. They know everything
		d. They can run the whole production line without the intervention of a human

Question 43

Define what a KPI is and why we need to monitor them.
 

Question 44

What is Hansei?

		a. Humility
		b. Motivation
		c. Reflection
		d. Improvement

Question 45

What is meant by Genchi Genbutsu ?

		a. Find out for yourself
		b. Go and See
		c. Leave and Look Away
		d. Never look back

Question 46

What is the device to make sure there are no errors in the work?

		a. Andon
		b. Poka-yoke
		c. Muri
		d. Kanban

Question 47

In an M & I flowchart, what visual representation denotes a problem

		a. dashed arrow line
		b. striped arrow
		c. spiked cloud
		d. an upside down triangle

Question 48

Which of the following would cause or be considered Muda?

		a. Bottlenecking in production
		b. Grouping machines and professional specialties, on the work floor, of the same process together.
		c. Batch and Queue Processing
		d. All of the Above

Question 49

What does the Japanese word “sensei” mean?

		a. Mentor
		b. Boss
		c. Friend
		d. Father

Question 50

Which of these does Flow not lead to?

		a. Good quality
		b. Low cost
		c. Higher inventory stock
		d. Short delivery time

uestion 51

What is the best thing you can do when problem solving?

	A.	Blame the problem on a coworker
	B.	Identify the problem
	C.	Analyze the problem
	D.	Know exactly where the problem is occurring

Question 52

Look at the attached image and Calculate the Process Capacity if
You are working a 10 hour shift with three (3) -10 minute breaks and a 5 minute cleanup at the end.
Process Capacity = {total available time / manual+automatic time} = { (10*60*60 – 3*10*60 – 5*60 ) / (85+105+360)} = 61.64
 
 

Question 53

What step should the question Why be first asked?

	A.	5 Develop Countermeasures
	B.	3 Set a Target
	C.	2 break down the problem
	D.	4 Analyze Root Cause

 

Question 54

Why is Hansei important in Toyota?
 
 
Q 55
What happened when GM tried to carbon-copy TPS?
 
List and explain how employees at Toyota are motivated?
 
Why is challenging your suppliers and partners a good idea?
 
List and describe the 8 steps of the A3 Form Toyota uses to document problems and solutions.
 
Explain the principle of the five why concept utilized in product development and problem solving within Toyota, and why the ask why 5 times in repetition.
 
What is the best part about gaining consensus with everyone according to Toyota?
 
Q 43 Define what a KPI is and why we need to monitor them.
 
Q 54 Why is Hansei important in Toyota?
 
q 55 What happened when GM tried to carbon-copy TPS?
 
q 56 List and explain how employees at Toyota are motivated?
 
q 57 Why is challenging your suppliers and partners a good idea?
 
q 58 List and describe the 8 steps of the A3 Form Toyota uses to document problems and solutions.
 
q 59 Explain the principle of the five why concept utilized in product development and problem solving within Toyota, and why the ask why 5 times in repetition.
 
 
q 60 What is the best part about gaining consensus with everyone according to Toyota?
 
Q4 Explain the differences between companies that operate with enabling bureaucracies, and those that operate with coercive bureaucracies.
Q5 List and describe the 8 steps of the A3 Form Toyota uses to document problems and solutions.
Q6 How can a company guarantee quality?
Q7 List and explain how employees at Toyota are motivated?
Q8 Explain the principle of the five why concept utilized in product development and problem solving within Toyota, and why the ask why 5 times in repetition.
Q9 What is the best part about gaining consensus with everyone according to Toyota?
Q13 Why is Hansei important in Toyota?
Q27 Define what a KPI is and why we need to monitor them.
 
Q3 What is Toyota’s idea of “change to order” rather than “build to order”?
Q4 While an Andon system is indeed an important device for quality or defect communication between workers, can a company go overboard with this ideology?
Q5 Why does being process-oriented lead to better outcomes than result-oriented?
Q6 List and explain how employees at Toyota are motivated?
Q7 List and describe the 8 steps of the A3 Form Toyota uses to document problems and solutions.
Q8 Explain the principle of the five why concept utilized in product development and problem solving within Toyota, and why the ask why 5 times in repetition.
Q12 Why is Hansei important in Toyota?
Q27 Define what a KPI is and why we need to monitor them.

Engineering homework help