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| Question | Answer |
| Manufacturing is important to the economy because why? | It generates wealth, supports service industries, and adds value to products. |
| If manufacturing lead time of an item is reduced by 50%, what happens to the WIP? | The WIP is reduced by approximately 50% |
| What are the 4 inputs to manufacturing planning and control? | Product description, process description, available facilities, and quantities to be produced. |
| Which level in the Manufacturing Planning and Control (MPC) system has the longest planning horizon and the least level of detail? | Strategic Business Plan |
| What type of planning is concerned with the process of checking whether the critical resources are available to support the preliminary MPS? | Rough-Cut Capacity Planning |
| What is a BOM planning structure? | Bill of Materials |
| A company wants to produce on avg 500 units/month over the first quarter of the year at a uniform rate. The first three months have 19, 20, and 21 days. How much should the company produce each day to achieve a level structure? | 500 * 3 Months = 1500 25 units *60 days = 1500 25 units/day for level structure |
| For the purpose of production planning, product groups should be established on the basis of what? | Similarity of Manufacturing Processes |
| What is a vital link in the production planning system that forms a vital link between sales and production and what manufacturing will actually build. If also allows orders to be promised or not. | Master Production Schedule |
| Which basic production planning strategy will build inventory and avoid the costs of excess capacity? | Production Leveling |
| The routine that Toyota follows to establish a problem solving culture of learning the methodology of grasping the current condition, establishing the target condition, and then following a series of PDCA actions to navigate obstacles is called what? | Kata |
| A work center consists of 2 machines working 8 hours a day, and 5 days per week. Historically, utilization has been 80% and the efficiency 90%. The effective capacity, to the nearest hour, would be what? | Rated Capacity = available time X utilization X efficiency Avail Time = 2 * 8 * 5 = 80 hrs R Capacity = 80 * .80 * .90 = 57.6 standard hrs |
| The early error detection system that Sakichi Toyoda designed for his mother's weaving loom and ultimately patented, is commonly referred to in the Toyoda Production System as what? | Jidoka |
| The time for those production activities that actually transform the product in a way the customer is willing to pay for is called, ____________ time? | Value-Added Time |
| CHECK! Parent item A requires 1 each of component B and C. Both B and C are processed on Work Center 20. which has an available capacity of 40 hours. The setup time for component B is 1 hour and the run time is 0.30 per piece. For Component C, setup time is 2 hours and the run time is 0.20 hours per piece. Calculate the number of B's and C's that can be produced? | ? |
| In most organizations, what % of the total manufacturing leadtime is non-value added? | 95%!!! |
| Two basic components of Lean Manufacturing that establish discipline, workplace organization and the ability to see waste quickly are what? | 5S and Visual controls |
| A work center was available for work 80 hours, produced 74 standard hours of work and actually worked 67 hours. What is the efficiency of the work center (closest 0.1%)? | Eff Rate = std hrs worked / hrs actual work Standard Hours / Actual Work = 110.4% |
| In order for a Pull system to run most efficiently and effectively in a manufacturing plant, two components are necessary. What are these two components? | Supermarket Bins and Kanban Cards (or Kanban System) |
| What is the purpose of LEAN? | To eliminate waste |
| What is a KANBAN system used to control? | The Pull System |
| What are the 5S Visual Controls? | 1. Sort 2. Shine 3. Straighten 4. Stabilize 5. Sustain *Safety |
| What is the basic definition of visual controls? | They are waste elimination tools that use audio/visual signals to provide an immediate understanding of a situation or condition. |
| What is the process of Standard Work as a LEAN control? | Tasks completed in an organized best known sequence using the most effective combination of resources. |
| What is the purpose of Source Inspections and Poka-Yoke? | It is to build error proofing into the system. |
| What is the purpose of setup reduction within LEAN? | To minimize equipment downtime between product change overs. |
| What is Heijunka? | Levelized Production that applies to the even distribution of workloads and product variety. |
| What is cellular manufacturing? | Link manual and machine operations into the most efficient combination to maximize value added content while minimizing waste. |
| What are the six major losses within TPM (Total Productive Maintenance)? | 1. Breakdown Losses 2. Setup and Adjustment Losses 3. Idling and Minor Stoppages 4. Reduced Speed Losses 5. Quality Defects and Rework 6. Start-up and Yield Losses |
| What is OEE? | Overall Equipment Effectiveness |
| What are the four levels of the Manufacturing Planning System? | 1. Strategic Business Plan 2. Production Plan 3. Master Production Schedule 4. Material Requirements Plan |
| What is the key to effective Production Planning? | Match Priority w/ Capacity |
| Which planning level is concerned with the resources needed in each period and the availability of needed resources. | The Production Plan |
| What is the typical planning horizon of the MPS and MRP? | 3 to 18 months |
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