ECO-Mock Test With Answers

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ECOMOCK TEST

1. In a job shop environment, which of the following are true? I. Less work in process inventory increases lead times II. Longer queues increase lead times III. More work-in-process means increased lead times

A) I and II B) I and III C) II and III D) I, II, and III

2. Lot traceability of a product from raw component to the customer would be worth maintaining in which of the following industries? I. Toy industry II. Food manufacturing/distribution III. Pharmaceutical manufacturing


3. The line should be balanced in an assembly operation in order to:

A) Allow operators to change assembly lines. B) Maximize line output. C) Develop labor standards for costing parts. D) Minimize the necessary parts stored on the line.

4. There are three jobs to be completed on the schedule with the following critical ratios associated with the jobs as follows:

Job 123 0.75 Job 456 0.95 Job 789 1.10

Which job should be processed first?

A) Job 123 B) Job 456 C) Job 789 D) Not enough information to decide

5. In a job shop environment, which of the following elements of lead-time is generally the greatest?

A) Queue time B) Run time C) Setup time D) Move time

6. Which of the following statements are true regarding lead time? I. An overloaded factory floor increases lead time. II. Lead time will decrease when input equals output. III. Lead time will decrease if output exceeds input.


7. When the Master Production Schedule is overstated, priorities may become unclear because: I. Valid due dates will not be listed on the dispatch lists II. Quantities needed will not be valid III. Dispatch lists will have split routings


8. A supplier has just increased the lead time to the customer. The customer will respond by:

A) Decreasing the capacity utilization factors. B) Increasing the safety stock. C) Changing the gross requirements in the system. D) Delaying the scheduled receipts in the system.

9. A primary operation is best defined as:

A) An alternate operation used to manufacture. B) A manufacturing operation normally used as part of a routing to produce a part. C) The first operation in a sequence. D) The first work center to consume a part.

10. Using the critical ratio, jobs which are ahead of schedule carry a ratio of:

A) Greater than 1.0. B) Less than 1.0. C) Equal to 1.0. D) None of the above

11. Which of the following is synonymous with detailed scheduling? A) Infinite loading B) Operations scheduling C) GANTT charts D) Pert charts

12. When orders are assigned to the factory without any restrictions on capacity, this is known as:

A) Smoothed capacity load. B) Overloaded. C) Unsmoothed load. D) Lumpy capacity load.

13. Which of the following is affected when input does not match output?

I. Lot sizes II. Lead times III. Queue sizes


14. All of the following are job sequence rules for dispatching EXCEPT:

A) First come, first served B) Earliest job due date C) Shortest process time D) Highest machine utilization

15. Backlogs should be held:

A) On the shop floor. B) At the customer. C) In production control. D) In the warehouse.

16. Which of the following best describes the forward scheduling technique? I. Begins with a known start date and calculates a completion date for an order II. Dates generated are earliest start dates for each operation III. Orders are loaded for each operation, first to last


17. The term "linearity" means:

A) The line capacity is balanced from beginning to end. B) Production is at a constant or level rate. C) A single source supplies each component. D) The master schedule is not overloaded.

18. Which of the following terms or philosophies are synonymous with zero inventories? I. Just-in-Time II. Stockless production III. Zero defects


19. Which of the following will be true if the cumulative lead time of a product is longer than the MPS planning horizon?

A) Orders for long lead time components will be released late. B) Orders for long lead time components will be released early. C) Order point can be used for the longest lead time items without affecting priorities.

D) There is no impact.

20. Which of the following statements are generally included in a routing? I. Operations to be performed and their sequence II. Work centers involved in manufacturing III. The raw materials needed to produce


21. A job status report would show:

A) Costs accumulated for the job. B) The input and output of every work center. C) The plan for completing a job and the progress versus the plan. D) The job priority at each work center.

22. Which of the following best defines a gateway work center?

A) The work center which is the bottleneck B) The work center with the first operation C) The work center just before the final assembly D) The work center which is last

23. Which of the following are true regarding operations scheduling?

A) It is a short-range scheduling technique B) It is a medium-range scheduling technique C) It is a long-range scheduling technique D) None of the above

24. Which of the following best describes back scheduling?

A) Start with the current date and calculate the order due date by the time of each operation B) Rescheduling jobs where the input is greater than output C) Starting with the order due date, calculate the start date of the order by going back through each operation D) Eliminating capacity availability by working back through the operations

25. The process of shutting down a production line or machine upon identification of a defect is:

A) Down time. B) A capacity constraint. C) Simplification. D) Autonomation.

26. In a job shop environment, it may not be possible to convert all areas to a "flow" shop. Wherever possible the "flow" can be accomplished by: I. Reducing setup times (quick changeover) II. Reducing or eliminating queue times III. Lowering defects towards a zero goal IV. Cross-training workers

A) I and III

B) I, II, and III C) II, III, and IV D) I, II, III, and IV

27. In order to accurately report shop floor data, which of the following must be in place?

A) Shop floor bar code system B) Work in process inventory balances C) Work centers defined to the system D) Firm planned orders

28. Preventive maintenance is important in all companies, but is usually the smallest portion of the maintenance budget. For a lean manufacturing environment, preventive maintenance is critical for which of the following reasons? I. Unplanned downtime due to breakdowns is avoided II. It allows the production line to produce saleable units III. It extends the useful life of equipment, thereby delaying investment in new equipment


29. If the input to a work center is equal to the output from the work center, then which of the following is true? I. Backlogs are constant II. Lead time remains constant III. Lead time will increase slightly


30. In a flow manufacturing environment, a decision has been made to increase the number of kanban containers being used in the operation. The net effect on WIP will be:

A) To decrease WIP. B) To keep WIP the same. C) To increase WIP. D) Dependent on the container quantities.

31. Which of the following are scheduled in manufacturing lead time? I. Time to purchase II. Queue time III. Run time


32. Given the following information for a work center:Machines = 2 Operations per shift = 3 Shifts per day = 1

Days worked per week = 4 Hours worked per shift = 10 Machine utilization = 90% Operator efficiency = 80% If the weekly load on the work center is 72 hours, the work center is:

A) Overloaded B) Underloaded C) In balance D) Not enough data

33. All of the following are part of starting a Just-in-Time implementation EXCEPT:

A) Conduct some general JIT education B) Complete a detailed implementation plan for the complete project C) Pick a pilot project D) Review pilot project as a learning experiment

34. Which of the following reflects the order in which Computer Integrated Manufacturing (CIM) should be implemented?

A) CIM should be worked on early to create a flexible manufacturing system. B) CIM should be implemented after the environment has been simplified, organized, and focused. C) CIM can only be implemented in very large, resource rich corporations. D) CIM should be implemented first where labor is high cost.

35. Which of the following would be caused by the waste of overproduction? I. Extra material handling II. Quality defects III. Extra administrative costs IV. Wrong parts which are not needed

A) I, II, and III B) I, III, and IV C) II, III, and IV D) I, II, III, and IV

36. Calculate the standard hours available in an 8 hour shift if the loss time factor is 7% and the machine efficiency is 90%. (Round to the nearest hundredth.)

A) 5.43 B) 6.24 C) 6.70 D) 7.42

37. Shop capacity is directly affected by which of the following? I. Operator efficiency II. Number of released orders on the floor at one time III. Number of shifts operating IV. Level of maintenance

A) I, II, and III B) I, III, and IV C) II, III, and IV D) I, II, III, and IV

38. In order to analyze a material flow in a manufacturing process, which of the following tools will be most helpful?

A) Statistical process control chart B) Fishbone diagram C) Process flow chart D) Force field analysis

39. An order for 200 of a product is processed on work centers 101 and 102. The setup time on work center 101 is 60 minutes and the run time is 3 minutes each. The setup time on work center 102 is 50 minutes and the run time is 5 minutes each. The wait time between each operation is 3 hours and the move time between 101 and 102 is 30 minutes. The wait time after work center 102 is 4 hours with a move time to storage of 20 minutes. What is the total manufacturing lead time for the order?

A) 28.5 hours B) 29.3 hours C) 36.3 hours D) 39.4 hours

40. Managing the shop floor more effectively can improve customer service in which of the following ways? I. Replenishing stock orders on time II. Improving parts availability III. Improving inventory accuracy


41. In which of the following businesses can shop floor control procedures be best applied? I. Make-to-stock II. Make-to-order III. Assemble-to-order


42. Floor stocks can be best defined as:

A) Components which have been issued and moved to the floor. B) Raw steel to be formed. C) Inexpensive parts held in the factory for use without requisitions by workers. D) Inventory held on the floor of the warehouse.

43. Given the following information for a work center:Machines = 2 Operations per shift = 3 Shifts per day = 1 Days worked per week = 4 Hours worked per shift = 10 Machine utilization = 90% Operator efficiency = 80%

The weekly available capacity at the above work center is: (Rounded to the nearest whole standard hour.)

A) 50 B) 55 C) 58 D) 60

44. Which of the following would best describe the term dedicated capacity? I. A machine which is designated to produce only one item II. Special equipment designed specifically to produce a small group of items III. The 20% committed capacity a customer has taken


45. Setup time reduction in a JIT implementation is very important because: I. Small lot sizes reduce inventory II. Production output will increase III. All of the products can be made constantly


46. Kanban can be best described by which of the following?

A) Just-in-Time vendor delivery system B) A Japanese form of statistical process control C) A pull system used for signaling the previous operation that parts are needed D) A work team improvement process

47. Which of the following are benefits of a pull system in production? I. Lead time reduction II. Work in process reduction III. Problems become apparent so resolution takes place


48. Which of the following would be found in a focused factory? A) Logical flows of materials through the factory B) Plant layout by function C) Increased paperwork to support the operation D) Increased product variety

49. By increasing the capacity at the bottleneck work center, which of the following will occur? I. Manufacturing lead times will be shortened II. Work in process inventory will be reduced III. Scrap will be reduced


50. The total time included in an operation's duration includes all of the following EXCEPT:

A) Setup time B) Wait time after completion C) Run time of operation D) Tooling

51. In order to efficiently ensure the quality of a product is adequate, companies will take a predetermined number of samples and have a preset number of samples that must pass in order to accept the entire lot of product. This predetermined acceptance/rejection rate is established in the:

A) Control charts. B) Sampling plan. C) Supplier evaluation. D) Receipt routing.

52. Which of the following would be true regarding a quality and a process?

A) Quality can be inspected into a process. B) The further into the process the more a defect costs. C) Statistical processing will ensure a perfect process. D) If the customer accepts a partial defect than the quality is adequate.

53. One of the greatest wastes to be found in manufacturing is the unexpected downtime of a critical machine. This downtime will cause capacity to be eliminated, parts to be backlogged and labor resources to be wasted while maintenance works on the machine. It also causes the schedule to be changed and customer deliveries to be delayed. This unplanned situation can be minimized by implementing:

A) Preventive maintenance scheduling software. B) A quality engineering program. C) Total productive maintenance. D) A capacity cushion for these emergencies.

54. Based on the following information, what is the lost time factor?Planned hours 10 Standard hours earned 8 Actual hours worked 10

A) 0.2 B) 0.25 C) 2 D) 4

55. During a continuous improvement implementation, excess labor and capacity usually become available. This provides an opportunity to:

A) Layoff the excess labor to reduce costs. B) Lease the open space to form an incubator for small companies. C) Cross-train the excess labor for other jobs or preventive maintenance.

D) Clean the facility.

56. Benchmarking, as it relates to business performance, can be best defined as:

A) A search for industry "best practices" that lead to superior business performance. B) Finding the optimum performance of a machine. C) Finding the target operation performance in statistical process control. D) Meeting the due date in an optimal consistent manner.

57. Which of the following statements best describes the term Total Quality Control (TQC)?

A) Statistical tests of product attributes to identify sources of defects B) Elimination of inspection stations on the shop floor C) The total cost of quality is below plan each year D) The integrated process of producing the total product characteristics to meet customer expectations

58. Many companies implement a management approach to long term success through customer satisfaction. This management approach is better known as:

A) Total Quality Management (TQM). B) Total Quality Control (TQC). C) Total Productive Quality (TPQ). D) Total Process Management (TPM).

59. The costs of inspecting material upon arrival, during manufacture, in laboratory tests, and by outside inspectors are classified as:

A) Warranty costs. B) Statistical process costs. C) Appraisal costs. D) Prevention costs.

60. A company has just received 100 parts from a supplier. How many samples would need to be taken to determine if the complete load is acceptable?

A) 10% B) 30% C) 50% D) Depends on the supplier's reliability and quality history

61. Which of the following are process analysis tools? I. Flowcharts II. Scatter diagrams III. GANTT chart

A) I B) I and II C) I and III D) I, II, and III

62. In an assembly flow line where the manufacture of the finished serialized product takes less than an hour, where would be the most appropriate location for a data collection device (bar code)?

A) At the beginning of the line B) In the middle of the line C) At the end of the line

D) All of the above locations

63. If labor productivity continues to rise, yet the labor cost per unit is also rising, what can be concluded?

A) The rate of increase for labor costs is greater than the productivity increase. B) Labor productivity will soon decline. C) Labor costs must decline. D) None of the above

64. Often times, quality problems can be traced to management's role in the quality process. Which of the following contribute to inferior quality? I. Quality objectives are not clearly stated. II. Management expects perfect quality. III. Inferior quality is attributed to inferior people. IV. Quality standard measurements vary with business conditions.

A) I, II, and IV B) I, II, and III C) I, III, and IV D) I, II, III, and IV

65. When a quality problem surfaces within a process, the problem can be identified and analyzed using a cause and effect diagram. This cause and effect analysis is usually made using a:

A) Fishbone diagram. B) SPC chart. C) Force field analysis. D) Pareto analysis.

66. Which of the following is the most important element of a total quality control (TQC) program?

A) Process control B) Line stop capability C) Project by project improvement D) None of the above

67. Which of the following would be good measures to report to workers regarding the progress of the JIT implementation? I. Higher machine utilization II. Reduced floor space III. Reduced lead time IV. Reduced inventory

A) I, II, and IV B) I, III, and IV C) II, III, and IV D) I, II, III, and IV

68. Under the TQC (Total Quality Control) philosophy, a customer is defined as: A) Another company you sell to B) A division or department to which you send products C) A following operation D) All of the above

69. Which of the following can be considered factors in the success of an SGIA?

I. Management support and commitment II. Clear goals always established by management III. Educating and training all personnel IV. Recognizing and rewarding the group

A) I, II, and IV B) I, III, and IV C) II, III, and IV D) I, II, III, and IV

70. A company has an ongoing cycle count program in which errors are identified for correction. Which of the following best describes the action which should be taken when an error in the inventory balance is identified?

A) Adjust the inventory balance to reflect the count. B) Count the inventory again and adjust the record. C) Count the inventory again and identify the cause of the error before adjusting the record. D) Wait until the next count on the next cycle. If it is off again adjust the record.

71. Indirect labor can be best defined as:

A) Non-essential labor. B) Labor not directly associated with production. C) Final assembly labor. D) None of the above

72. Which of the following elements of manufacturing lead time is generally the longest?

A) Move time B) Setup time C) Run time D) Queue time

73. The process of finishing product A at work center 101 has just been completed. In order to prepare for running product B at this workstation, different tooling must be installed. This process is called:

A) Interoperation time. B) Changeover. C) Tooling reconfiguration. D) Queue time.

74. Given the following information on a work center:Machines = 3 Operations per shift = 2 Shifts per day = 1 Days worked per week = 5 Hours worked per shift = 8 Machine utilization = 80% Operator efficiency = 90% If the weekly load on the work center is 90 hours, the work center is:

A) Overloaded B) Under loaded C) In balance D) Not enough data

75. A cost report has just been generated which shows a large material variance between standard cost and the actual price paid. You should call:

A) Accounting. B) Purchasing. C) Engineering. D) Factory manager.

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ECO-Mock Test With Answers