ANSWER KEY Industrial Engineering Reviewer for Mechanical Engineer

Process Optimization
 
1. Which of the following methodologies focuses on reducing waste while maintaining productivity?
A. Total Quality Management (TQM)
B. Lean Manufacturing
C. Just-In-Time (JIT)
D. Benchmarking
Answer: B
Explanation: Lean Manufacturing focuses on minimizing waste while ensuring that production remains efficient and cost-effective.
 
2. What is the primary goal of Six Sigma in process optimization?
A. Reduce inventory levels
B. Improve customer satisfaction
C. Minimize process variations and defects
D. Increase production speed
Answer: C
Explanation: Six Sigma is a data-driven methodology that aims to reduce defects and process variations to achieve near-perfect quality.
 
3. In the DMAIC cycle of Six Sigma, what does "A" stand for?
A. Adjust
B. Analyze
C. Accelerate
D. Audit
Answer: B
Explanation: DMAIC stands for Define, Measure, Analyze, Improve, and Control, which are the steps in process improvement.
 
4. The 5S methodology aims to improve workplace organization. What does "Seiton" refer to?
A. Sort
B. Set in order
C. Shine
D. Standardize
Answer: B
Explanation: Seiton means organizing tools and materials in a way that promotes efficiency and easy accessibility.
 
5. Which performance metric is used to measure the efficiency of a manufacturing process?
A. Overall Equipment Effectiveness (OEE)
B. Supply Chain Agility
C. Total Cost of Ownership (TCO)
D. Supplier Lead Time
Answer: A
Explanation: OEE is a key indicator of manufacturing efficiency, measuring availability, performance, and quality.
 
6. What does the "Kanban" system primarily focus on in Lean Manufacturing?
A. Increasing production speed
B. Controlling inventory levels and work-in-progress
C. Improving machine efficiency
D. Reducing employee workload
Answer: B
Explanation: Kanban is a pull-based system that signals when more materials are needed, preventing overproduction and excess inventory.
 
7. The "bottleneck" in a production process is defined as:
A. The process step with the highest efficiency
B. A temporary storage area for raw materials
C. A machine breakdown in the production line
D. The slowest step that limits overall production capacity
Answer: D
Explanation: Identifying and improving bottlenecks increases throughput and reduces delays in manufacturing.
 
8. In Value Stream Mapping (VSM), what does the term "non-value-added activity" refer to?
A. A process that improves quality
B. A process that adds cost but no value to the customer
C. A mandatory government regulation
D. A step that increases production speed
Answer: B
Explanation: Lean Manufacturing aims to eliminate non-value-added activities, such as excess movement and waiting times.
 
Facilities Planning
 
9. What is the primary objective of facility layout planning?
A. Reduce material handling costs
B. Increase product design flexibility
C. Decrease employee wages
D. Improve supplier relationships
Answer: A
Explanation: A well-planned facility layout minimizes unnecessary movement of materials and workers, improving efficiency.
 
10. What type of layout is best suited for high-variety, low-volume production?
A. Product Layout
B. Process Layout
C. Fixed-Position Layout
D. Cellular Layout
Answer: B
Explanation: Process layouts are used when producing a variety of products in small batches, grouping similar processes together.
 
11. In facility design, what does “muther’s systematic layout planning” primarily focus on?
A. Reducing material waste
B. Optimizing space and relationships between areas
C. Lowering transportation costs
D. Improving energy efficiency
Answer: B
Explanation: Muther's Systematic Layout Planning (SLP) provides a structured approach to arranging workspaces efficiently.
 
12. The ideal facility layout should consider which of the following factors?
A. Process flow
B. Worker comfort
C. Safety regulations
D. All of the above
Answer: D
Explanation: An efficient facility layout should improve productivity, ensure worker comfort, and adhere to safety standards.
 
13. Which type of manufacturing system uses workstations arranged in a sequence to produce a continuous flow of products?
A. Batch production
B. Job-shop production
C. Assembly line production
D. Project-based production
Answer: C
Explanation: Assembly line production is designed for mass production, ensuring a smooth workflow with minimal disruptions.
 
14. What is the primary advantage of a cellular manufacturing layout?
A. Reduces labor costs by hiring fewer employees
B. Increases flexibility and reduces setup time
C. Eliminates the need for quality control
D. Uses only manual assembly processes
Answer: B
Explanation: Cellular manufacturing groups machines and workstations efficiently to reduce movement and improve productivity.
 
15. In facility planning, an "affinity diagram" is used for:
A. Organizing ideas based on their relationships
B. Measuring equipment efficiency
C. Monitoring supplier performance
D. Evaluating product durability
Answer: A
Explanation: Affinity diagrams help categorize ideas during the planning and decision-making process.
 
16. What type of facility layout is most suitable for shipbuilding or aircraft manufacturing?
A. Product Layout
B. Fixed-Position Layout
C. Process Layout
D. Hybrid Layout
Answer: B
Explanation: In a fixed-position layout, the product remains stationary while workers and materials move around it, which is ideal for large-scale projects.
 
Quality Control
 
17. What is the primary purpose of statistical process control (SPC)?
A. Reduce labor costs
B. Ensure product quality by monitoring processes
C. Improve customer service
D. Minimize raw material usage
Answer: B
Explanation: SPC uses statistical methods to track production quality and detect variations early.
 
18. The Ishikawa diagram is commonly used for:
A. Identifying causes of defects
B. Inventory management
C. Facility layout optimization
D. Demand forecasting
Answer: A
Explanation: The Ishikawa (Fishbone) diagram helps identify root causes of quality issues.
 
19. In the Taguchi method, what is the main goal?
A. Reduce product costs
B. Improve marketing strategies
C. Increase workforce productivity
D. Optimize process design to minimize variation
Answer: D
Explanation: The Taguchi method focuses on designing robust processes that produce consistent quality.
 
20. Which ISO standard is associated with quality management systems?
A. ISO 9001
B. ISO 14001
C. ISO 45001
D. ISO 50001
Answer: A
Explanation: ISO 9001 outlines requirements for quality management systems in various industries.
 
21. A control chart is used to:
A. Monitor process stability
B. Increase production speed
C. Reduce employee errors
D. Improve facility layout
Answer: A
Explanation: Control charts track process variations to maintain quality.
 
22. The Pareto Principle states that:
A. 20% of causes contribute to 80% of problems
B. All defects are equally important
C. Quality control should focus only on major defects
D. 50% of quality issues come from production errors
Answer: A
Explanation: The Pareto Principle (80/20 Rule) is used in quality control to prioritize efforts on the most significant problems.
 
23. In a quality inspection process, which sampling technique ensures every product has an equal chance of being selected?
A. Stratified Sampling
B. Random Sampling
C. Systematic Sampling
D. Judgmental Sampling
Answer: B
Explanation: Random sampling ensures unbiased selection of items for quality inspection, reducing systematic errors.
 
Supply Chain Management
 
24. The Bullwhip Effect in supply chain management refers to:
A. Inventory shortages
B. Demand fluctuations causing supply chain inefficiencies
C. Supplier delivery delays
D. Excess production costs
Answer: B
Explanation: The Bullwhip Effect occurs when small demand changes amplify through the supply chain.
 
25. What is the primary goal of Just-In-Time (JIT) inventory management?
A. Reduce storage costs and waste
B. Increase production speed
C. Improve product durability
D. Lower employee turnover
Answer: A
Explanation: JIT minimizes inventory holding costs by aligning production with demand.
 
26. Economic Order Quantity (EOQ) is used to:
A. Optimize order quantity to minimize costs
B. Maximize warehouse space
C. Improve product design
D. Increase supplier competition
Answer: A
Explanation: EOQ helps determine the most cost-effective quantity to order.
 
27. Lead time in supply chain refers to:
A. Time required to manufacture a product
B. Time taken to deliver materials after placing an order
C. Employee training duration
D. Quality inspection time
Answer: B
Explanation: Lead time includes order processing, production, and shipping duration.
 
28. The purpose of safety stock in inventory management is to:
A. Reduce costs
B. Prevent stockouts due to demand fluctuations
C. Increase supplier lead time
D. Improve product quality
Answer: B
Explanation: Safety stock acts as a buffer against demand or supply uncertainties.
 
29. In logistics, the primary purpose of a warehouse management system (WMS) is to:
A. Reduce lead time
B. Optimize inventory tracking and storage
C. Increase product variety
D. Improve product design
Answer: B
Explanation: A WMS helps companies efficiently manage inventory, reduce errors, and improve order fulfillment.
 
30. What is the primary function of a third-party logistics (3PL) provider?
A. Manufacturing raw materials
B. Outsourcing logistics services such as warehousing and transportation
C. Developing product designs
D. Controlling quality assurance processes
Answer: B
Explanation: 3PL providers specialize in handling logistics operations, allowing companies to focus on core manufacturing activities.