APICS APICS Manufacturing Operations & Execution 2 — Questions and Answers
Question 1: What is the purpose of a 'kanban' system in lean manufacturing?
- To track employee training records
- To signal replenishment of materials or production of items through visual triggers (Correct answer)
- To schedule preventive maintenance
- To manage supplier invoices
Correct answer: To signal replenishment of materials or production of items through visual triggers
Kanban is a pull-based visual signaling system that authorizes production or material movement only when downstream demand exists.
Question 2: Which production layout arranges equipment in a U-shaped or linear cell designed to produce a family of similar products?
- Process layout (job shop)
- Fixed-position layout
- Cellular manufacturing layout (Correct answer)
- Product layout (assembly line)
Correct answer: Cellular manufacturing layout
Cellular manufacturing groups dissimilar machines together in a cell to complete a product family with minimal material handling.
Question 3: In APICS terminology, 'throughput' in the Theory of Constraints is defined as:
- Total units produced per day
- The rate at which the system generates money through sales (Correct answer)
- Machine utilization percentage
- Total labor hours consumed
Correct answer: The rate at which the system generates money through sales
TOC defines throughput as the rate at which the entire system generates revenue through actual sales, not just production output.
Question 4: What does 'poka-yoke' mean in lean/quality management?
- Continuous improvement through small steps
- A mistake-proofing device or method that prevents defects (Correct answer)
- A visual management board
- A standard operating procedure format
Correct answer: A mistake-proofing device or method that prevents defects
Poka-yoke (error-proofing) uses physical or process design features to make it impossible or immediately obvious when a mistake occurs.
Question 5: The 'five S' methodology in lean manufacturing stands for Sort, Set in Order, Shine, Standardize, and:
- Streamline
- Sustain (Correct answer)
- Simplify
- Synchronize
Correct answer: Sustain
The fifth S—Sustain—involves maintaining the discipline to keep the 5S improvements in place through training and audits.
Question 6: Which metric measures the percentage of orders shipped complete, on time, and damage-free on the first attempt?
- Fill rate
- On-time delivery (OTD)
- Perfect Order Fulfillment (Correct answer)
- Order cycle time
Correct answer: Perfect Order Fulfillment
Perfect Order Fulfillment tracks whether orders were delivered complete, on time, undamaged, and with accurate documentation.
APICS APICS Manufacturing Operations & Execution 2
What is the purpose of a 'kanban' system in lean manufacturing?