WORLD CLASS MANUFACTURING

SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

Preventive maintenance improves Material productivity Labour Machine Capital
A1 productivity productivity productivity 3

Basic work content + Basic work Basic work Basic work

Total work content = content – content + content –
Excess time
Excess time Ineffective time Ineffective time
A2 3
Materials, Machines, Methods,
Materials, Machines,
The resources utilized for production are Manpower Methods, Manpower, Machine,
A3 Machines Methods Manpower 1
Organizational
While setting Quality objective, ________ to be considered. Customer need Supplier need Worker need
A4 need 1
Capability
Capability maturity Capability Capability
CMM stands for monitoring
model model measuring model matching model
A5 1
Similar products or services are manufactured repeatedly using intermittent flow Continuous Job Shop Project
Batch Production
A6 is called as….. Production Production Production 1
A7 When Volume of Production is _______ then Process Layout is Feasible High Medium Low Average 1
When Volume of Production is High (Mass Production) then ___________ is Fixed Product
Process layout Product Layout Flexible Layout
A8 Feasible. Layout Layout 3
A9 Which of the following are the Determinants of Process Characteristics Volume Variety Flow All of them 2
Productivity is the ____ of production system. Measurement Efficiency Both (A) and (B) None of them
A10 3
Operation is a ________ process designed to convert input in to a valuable Conversion Frank B. Transition Production
A11 Product or Service Gilbreth 2
In a Process Strategy, High Variety & Low Volume should focus on Processes Product Both a & b None of them
A12 ____________ ? 3
In a Process Strategy, Low Variety & High Volume should focus on ____________ Processes Product Both a & b None of them
A13 1
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

A manufacturing set up of a reputed group is established to produce 110 units of

bicycles per month, that are"strictly tailormade" to everyorder's requirements. Processoriente Continuousprodu
Mass production Job production
The organization is in this business for a long time and is specialised in made-to- dproduction ction
order products.In your opinion, the type of production here is:-
A14 4
Vertical integration or outsourcing to manage with Operations & Supply is a Expansion of Business Backward Make or Buy Outsourcing
A15 decision also called as_____ Integration Decision Decision 4

& are the principal methods for achieving faster throughput of JIT,Qualityman
existingproducts. agementpractic Planning,Schedu
B1 Production,Quality es Cost,Quality ling 2
Which probability distribution uses discrete data having only two possible
B2 outcomes? Poisson Chi-square Normal Binomial 4

Greatermanufa Componentandc
The Supply Management is required to implement strategic activities except:- cturingcompeti Managementinfo ommoditystrate
B3 Supplybasestrategy tiveness rmationsystem gies 2

means involving employees to take preventive and corrective actions without

management approval. Employee Employee's
B4 TQ empowerment involvement CWQC 3

Assessment of
What is the first step in the planning process for WCM? the company’s
current Examining the
Setting up the manufacturing Assessing the Strategic
B5 Planning Team capabilities Competition Position 2
An approach to detect failures using sensitive instruments is referred to as:- Correctivemaintenan Predictivemaint Totalproductive Noneoftheabov
B6 ce enance maintenance e 2

For a successful supplier involvement in Global Manufacturting,various policies Makinglargewa

of supplier network were introduced except:- rehousestoacco Useofsmall,sidel
Useofstandardizedco mmodateallsup oadedtrucksands Becomeadedicat
B7 ntainers pliersmaterial hipmixedloads edsupplier 2
What is the usually accepted OEE score for manufacturers without TPM and/or
B8 leanprograms? 4 0.5 5 0.8 2
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

The world class Supply Management philosophy reflects those actions and values
responsible for continuous improvement of the design,development and
management processes of an organisation supply system with the objective of
improving its profitability and ensuring its survival as well as profitability and
survival of its customers and suppliers has been written by:- Burt,Doblerand Richard
B9 EdwardM.KnodJr. Starling DerekL.Waller J.Schonberger 2

In a small company,aproduct undergoes limited no.of operations.Operators

check the parts after the process and only good parts are sent forward for next
operation.There is no time loss due to inspection and there is no rejection from
customer.Those parts which are not ok are either reworked or scrapped.The
owner of the company feels that there is no need for spending time and money
for identification of process deviations or errors since only good out put is
delivered to the customer and customer is also happy with the quality and
delivery in this situation.

B10 1 False 3 4 2

Both in control
In terms of statistical process control (SPC), which of the following statement and is
holds true with reference to the variation within a stable system? It is predictable predictable
within a range of within a range of It is
B11 values. It is in control. values. controllable. 3
What important objective be considered in a competitive Indian environment
B12 Mix flexibility All of these Volume flexibility design flexibility 2

The purchasing lead time can be reduced by avoiding inspection of incoming

material at buyer's premises.This call By making BuyerplacestheIn
forimprovingthequalitystandardsandensuring:- short-term spectorforinspec Byself-
Bypayinghigherprices purchasingagre tingthemateriala certificationofqu
B13 tosuppliers ements tseller'spremises alitybysuppliers 4
Diamond represents ________ while plotting flow chart. Decision None of the
C1 Step in activity making Direction of flow above 2
P-D-C-A stands for Plan-Do- Proceed-Do- Proceed-Do-
C2 Plan-Do-check-Act correct-Act check-Act correct-Act 1
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

In a LEAN environment, operators are responsible for: Run the Execute direct
Maximizing the Meet customer processes requests to the
C3 output requirements assigned supervisor 2
While setting Quality objective, ________ to be considered.
C4 Material quality Customer need Market demand All of them 2

A map of the
Value Stream Mapping exercise begins with: A consensus Current Status
about how the (process and
Customer process should information Best Practices
C5 Specifications be executed flow) implementation 3

An employee with time available should: Perform the

next operation
Anticipate his on the Value
C6 Be punished Be rewarded work stream 4
C7 ISO emphasis on Prevention Inspection Rejection All of them 1
The main focus of any Continuous Improvement Project should be the Organizational
C8 elimination of... FTEs Flexibility Waste levels 3

Six Sigma
Choose the statement that is not correct: LEAN arose as a evolved as a Both
LEAN and Six Sigma Method to quality initiative methodologies
are both Process optimize auto to reduce are focused in
Improvement manufacturing variance in how to optimize
C9 Methodologies (Toyota); Motorola the Process flow 4

Apply the 5 G’s principles is a best practice to be followed during the problem GENBATSU –
solving exercise. Which one is not a “G” applicable here: Establish GENGITSU –
GENBUTSU – Examine rigorous Check facts and GENRI – Refer to
C10 physically the object measures figures the Theory 4
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

Is the usage of
any resource
Waste during the
Process, which is
not recognized
by the Customer
Is part of a as increasing the Cannot be seen
Is part of a Process Process and value they on the shop
C11 and always inevitable always evitable receive floor 3
Which of the following is responsible for quality objective? Top level Middle level Frontline
C12 management management management All of them 1

monitor the
The role of management is to effectiveness of
C13 provide Resources define EMS the system All of them 4

What is a typical semi value added activity (activity needed, but not providing
directly value for the Customer)? Rework to Training to bring
Check to ensure correct employee to Searching
C14 compliance mistakes desired standard documents 3

Among the tools of TQM, the tool ordinarily used to aid in understanding the
sequence of events through which a product travels is a
C15 Pareto chart Flow chart check sheet Taguchi map 2
The Japanese term “Jidoka” means ____________? Continuous
D1 Manual Correction Automation Autonomation Improvement 2

The first step in developing a project charterin Six sigma is to Investigate the
root causes of Identify the Calculate the
Identify the solutions the problem opportunity for final project
D2 to be tested being analyzed improvement benefits 3
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

As we calibrate our Measurement System to assure accurate data we frequently

encounter Bias which is the [ ] of a measured value from the [ ] value. Which of
the following terms can be inserted in the blanks to create a true statement? Deviation, hoped Spread, Mean of
D3 Deviation, true Spread, idea for the population 1

How do automotive companies mainly sell their new products? Through retail Via a trade Directly to
D4 Over the internet distributers magazine customers 4

perators
Edward Deming says, Quality is the responsibility of… Suppliers supplying working in Engineers Everyone
raw materials (inputs) Operations designing quality working for the
D5 O Department Design Organization 4
What is the main goal in the Measure phase ix Sigma ? Define precisely the Understand the Identify the root Implement
D6 Project Charter Problem causes actions 1
D7 Which term refers to a signaling device? muda kaizen poka-yoke kanban 4
Which of the following is used to create a model of the effect on an output by Correlation Linear Multiple
D8 the variation in two or more of the inputs? Coefficient X-Y Diagram Regression Regression 4
Which tool is not applicable in the Analyze phase of Six Sigma Cause and effect Design of
D9 Pareto Histogram diagram experiments 4

Lean principles
Which of the following statements is true of LEAN? Lean principles have been
Lean principles focus are separate developed over a Lean principles
on advanced body of lengthy period of include reducing
D10 statistical methods knowledge time. waste. 4
D11 Which word is not directly related to Six Sigma: Variability Precision Flow Accuracy 3
What name is often given to the Japanese “total quality approach‟ to removing Lean Continous
D12 anything that does not add value to the final product? Jobbing processes production Batch production Production 2
D13 Which term connotes waste and inefficiency? muda kaizen poka-yoke Kanban 1
"Kaizen" is a Japanese term meaning a foolproof Just-in-time a fishbone continuous
D14 mechanism (JIT) diagram improvement 4
Design of Experiments is a tool used during the Improve phase to understand the
D15 key variables that influence a result. True 0 3 4 1
Reducing unnecessary motion in operations can significantly improve
E1 throughput. Making these improvements is known as ____________? Eco-motion Ergonomics Economics Empowerment 1
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

Lean production involves Improvement of Elimination of Elimination of all Improvement of

E2 quality only cost only types of waste speed only 3
E3 JIT II is associated with vendor-managed inventory. True 0 3 4 1
Lean production relies on a specific throughput rate of the whole operation. This throughput
E4 is known as _____________? Output time time Kanban time Takt time 4
The ultimate objective in JIT objective is to minimize the amount of inventory on
E5 hand. 1 False 3 4 2

facilitate
Lean systems typically use layouts that: handling
are based on a job enable moving somewhat
shop in order to parts in large dissimilar
E6 handle variety lot sizes products all of them 1

Elimination of
Lean production involves Elimination of cost Improvement Improvement of all types of
E7 only of quality only speed only waste 4
Lean systems rely on worker specialization to achieve high productivity.
E8 True 0 3 4 1

One of the tools of lean production is SMED. What does this stand for? Single Motion Simple Motion
Single Minute Engineering and Exchange of SingleMinute
E9 Engineering Design ? Design Die Exchange of Die 4

Six Sigma
Choose the statement that is not correct: LEAN arose as a evolved as a Both
LEAN and Six Sigma Method to quality initiative methodologies
are both Process optimize auto to reduce are focused in
Improvement manufacturing variance in how to optimize
E10 Methodologies (Toyota); Motorola the Process flow 2
Lean systems use a "push" approach to operations to quickly get output to their
E11 customers. 1 False 3 4 2
E12 Using small lot sizes reduces the flexibility of a system. 1 False 3 4 2
Lowering inventory levels is a tactic to expose quality problems in a lean system.
E13 True 0 3 4 1
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

In a LEAN environment, operators are responsible for: Run the Execute direct
Maximizing the Meet customer processes requests to the
E14 output requirements assigned supervisor 1

What name is often given to the Japanese 'total approach‟ to removing anything Lean
that does not add value to the final product? production Continuous
E15 Jobbing processes processes processes. Batch processes 2
MRP is different from JIT in terms of Human
F1 Inventory Quality orientation All of them 1
Just-In-Time is Big lot size
F2 Single unit production production Both (A) and (B) None of them 4

Process
POK stands for Product ordering Ordering Production Plan Ordering
F3 Kanban Kanban Ordering Kanban Kanban 3

The following is (are) the prerequisite(s) for JIT.

Vendor should Worker should
produce defect be empowered
F4 Multi skilled workers free his own decision All of them 4

Just-In-Time (JIT) combines the benefits of Batch Job order

Job order production production and production and
F5 and Line production Line production Batch production None of them 1

The term that relates to matching the output rate with customer demand in a JIT
system is: single-minute
F6 fill rate takt time closed-loop JIT exchange of die 2

Cooperation
Just-in-time/SCM purchasing requires the following condition: between
Short-term purchasing and Continuous
F7 Many suppliers contracts suppliers competitive 3

The ultimate objective in a JIT system is: match demand

maintain low produce high with a balanced
F8 inventory quality minimize waste flow 4
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A
Just-In-Time is Big lot size
F9 Single unit production production Both (A) and (B) None of them 4
JIT does not believe in Over
F10 Quality production Human relations All of them 2
F11 Just-in-Time was successfully implemented by Toyota Honda Suzuki Volkswagen 1
F12 In Just-In-Time the vendor is to be viewed by the company as a Manager Worker Partner None of them 3
MRP is different from JIT in terms of Human
F13 Inventory Quality orientation All of them 4

In Just-In-Time system
Conveyance There is unequal
times are production at
F14 There is no delay balanced Both (A) and (B) different places 3

personnel/orga
Which one is not a building block of JIT? Akanban and small nizational
F15 lot sizes issues product design process design 2

Performance measurement is: The process of

The process of Competition The process of
G1 quantifying action. performance Industry action None of them 1

13Which kind of standards are those that are set arbitrarily to reflect some level Competitor Target Industry International
of performance that is regarded as appropriate or reasonable? performance performance performance performance
G2 standards standards. standards. standards 2
The origins of benchmarking as it is used today go back to which company?
G3 Toyota Xerox Ford Maruti 2
What do the letter ‘D’ and ‘I’ stand for in Deming’s cycle of improvement? Design and improve Define and Detect and Demand and
G4 improve improve improve 2

What matrix positions each factor according to its performance and its Importance Non-
importance? Performance performance Coreperformanc
G5 importance matrix matrix e matrix None of them 2
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

Scrapping any Scrapping any

The principles of the business process re-engineering (BPR) approach do NOT process line process line over
include: Scrapping any over two years three years old
process line over one old and starting and starting
years old and starting again from again from
G6 again from scratch. scratch. scratch. All them 2

A comparison between operations or parts of operations that are within the

same total organisation is called: Internal Industry External Standards
G7 benchmarking benchmarking benchmarking benchmarking 1

May not win

extra business
Qualifying competitive factors are those which: if the operation
improves its
performance
but can
certainly lose
business if
performance
falls below a Directly win
Directly win business particular business for the
G8 for the operation. point. operation. None of them 2

Benchmarking against external organisations that do not compete directly in Non-competitive

the same markets is called: Practice competitive benchmarking Industry
G9 benchmarking benchmarking benchmarking 3

XYZcompanyidentifiesthecausesofgaps.Themaingapbetween
thefirmscurrentperformanceandthefirmbenchmarked.Thiscanbecategorizedas:- Lack of
G10 communication Survey Analysis None of them 3
Improvement efforts are determined by: Priorities for future
G11 output. Competition Industry All of them 4
SR.NO DESCRIPTION OPTION1 OPTION2 OPTION3 OPTION4 A

Which of the following is regarded as a fundamental flaw in the whole concept It limits It limits It limits
of benchmarking? It limits improvements improvements to improvements
improvements to to Industry competitor to International
currently accepted accepted accepted accepted
methods of methods of methods of methods of
G12 operating. operating. operating. operating 1

What approach is used to compare organization operations with those of other Govt
companies? Recommendatio Quality
G13 Benchmarking. target setting ns Standards 1

Benchmarking against external organisations that do not compete directly in the Practice
same markets is called: External benchmarking Non-competitive Xerox
G14 benchmarking benchmarking benchmarking 3
Performance relating to the five operations’ objectives can be plotted on which
G15 type of diagram? Quality Polar Scalar None of them 2
A quality criterion which can be measured is called a ___________? Quality Quality
H1 Quality variable component Quality attribute characteristic 3
A useful process improvement tool to search for the root cause of a problem is
H2 the ___________ process? 3 Whats 4 Whos 5 Whys 6 Wheres 3

Which of these is a quality variable for a motor car? Comfort of the Time to reach a Road holding Headlights are
H3 seating given speed ability working 1

The Theoretical
In a materials processing operation the design capacity is defined as Maximum
_____________? Output in A
The Theoretical Given Time. The
The Aggregate Maximum Most Likely
The Minimum Output Annual Output. Output in A Output In A
H4 Per Given Time. Time. ? Given Time. Given 3
What additional factor does Overall Equipment Effectiveness take into account
H5 which makes it more meaningful than efficiency or utilization? Flexibility Speed Cost Quality 1