Total Quality Management Questions and Answers – Lean Manufacturing Tools – One-piece Flow, Jidoka, Demand Management & Cellular Manufacturing

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This set of Total Quality Management Multiple Choice Questions & Answers (MCQs) focuses on “Lean Manufacturing Tools – One-piece Flow, Jidoka, Demand Management & Cellular Manufacturing”.

1. One-piece flow is also known as single-piece flow in manufacturing.
a) True
b) False
View Answer

Answer: a
Explanation: One-piece flow is also known as single-piece flow in manufacturing. It is quite common in lean organizations.

2. Which of the following is not an advantage of one-piece flow used in production?
a) Early detection of defects
b) Flexibility for customization
c) Reduction of amount of work in progress
d) Inflexible in meeting customer demands
View Answer

Answer: d
Explanation: Early detection of defects, flexibility for customization, and flexibility in meeting customer demands are the advantages of one-piece flow used in production in lean organizations. It also reduces the amount of work in progress.

3. Which of the following refers to the term ‘autonomation’?
a) Poka-yoke
b) Jidoka
c) Andon
d) 5S
View Answer

Answer: b
Explanation: The term Jidoka refers to ‘autonomation’. It is widely used in the Toyota Production System and Lean Manufacturing.
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4. Which of the following refers to ‘automation with a human touch’?
a) Autonomation
b) Automation
c) Kaizen
d) Benchmarking
View Answer

Answer: a
Explanation: Autonomation refers to ‘automation with a human touch’. It is also described as ‘intelligent automation’.

5. The first step in applying Jidoka is _______
a) Discovering abnormality
b) Stopping the process
c) Fixing the immediate problem
d) Investigating and solving the root cause
View Answer

Answer: a
Explanation: The first step in applying Jidoka is discovering abnormality followed by stopping the process. After this, the immediate problem is fixed. At the end, investigation and solving the root cause is done.
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6. Which of the following is not the aim of demand management?
a) Improving forecast accuracy
b) Lessen investment in inventory
c) Creation of effective balance between demand and supply
d) Increase investment in inventory
View Answer

Answer: d
Explanation: Improving forecast accuracy, lessen investment in inventory, and creation of effective balance between demand and supply are the primary goals of demand management. It is a lean tool.

7. Which of the following is a type of plant layout in which machines and equipment are arranged according to their function?
a) Cellular layout
b) Process layout
c) Fixed position layout
d) Combined layout
View Answer

Answer: b
Explanation: In process layout, machines and equipment are arranged according to their function. For example, the drilling department, paint department etc.
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8. Which type of plant layout utilizes the merits of both process and product layout?
a) Product layout
b) Fixed position layout
c) Process layout
d) Combined layout
View Answer

Answer: d
Explanation: Combined layout utilizes the merits of both process and product layout. It is also known as hybrid layout.

9. In which type of plant layout machines are grouped into cells?
a) Fixed position layout
b) Cellular layout
c) Combined layout
d) Process layout
View Answer

Answer: b
Explanation: In cellular layout, machines are grouped into cells. It is commonly used in lean organizations.
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10. Which of the following is not an advantage of cellular manufacturing?
a) Increases flexibility
b) Increases transparency
c) Decreases overall productivity
d) Reduces changeover time
View Answer

Answer: c
Explanation: Cellular manufacturing increases flexibility. It introduces transparency. It reduces changeover time. In addition, it also increases productivity.

11. Product layout is generally used for standardized goods.
a) True
b) False
View Answer

Answer: a
Explanation: Product layout is generally used for standardized goods. The process layout is generally used for customized goods.

12. Which type of plant layout is also known as static layout?
a) Process layout
b) Cellular layout
c) Product layout
d) Fixed position layout.
View Answer

Answer: d
Explanation: Fixed position layout is also known as static layout. Examples: Manufacturing of hydraulic turbines, steam turbines, boilers, ships etc.

13. Cellular manufacturing _______ teamwork and communication between employees and departments.
a) enhances
b) depreciates
c) reduces
d) obstructs
View Answer

Answer: a
Explanation: Cellular manufacturing enhances teamwork and communication between employees and departments. It is a type of product layout where manufacturing is done in cells. It is widely used in lean organizations.

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Manish Bhojasia, a technology veteran with 20+ years @ Cisco & Wipro, is Founder and CTO at Sanfoundry. He lives in Bangalore, and focuses on development of Linux Kernel, SAN Technologies, Advanced C, Data Structures & Alogrithms. Stay connected with him at LinkedIn.

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