Mixed Deck — All Manufacturing and Production Topics Flashcards
100 cards from real Manufacturing and Production practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.
Read the first 20 Mixed Deck — All Manufacturing and Production Topics flashcards as text
Reshoring in US manufacturing refers to:
Answer: Bringing manufacturing operations back to the United States from overseas
Reshoring describes the trend of US companies returning manufacturing previously offshored to countries like China back to domestic facilities.
What does MTTR stand for in maintenance performance metrics?
Answer: Mean Time to Repair
MTTR (Mean Time to Repair) measures the average time required to diagnose, repair, and return a failed machine or component to operation.
What is a 'kanban' system primarily used for?
Answer: Controlling inventory and production pull signals
Kanban is a visual signaling system that controls the flow of work and inventory using a pull-based approach.
Machine guarding under OSHA is required when:
Answer: A machine has any point of operation, power transmission, or other moving parts that could injure workers
OSHA 29 CFR 1910.212 requires guarding on any machine part, function, or process that may cause bodily injury.
In lean, 'overproduction' is considered the worst waste because:
Answer: It generates all other wastes by producing more than needed
Overproduction leads to excess inventory, transportation, storage costs, and masks other process problems.
In production scheduling, 'job shop' scheduling refers to:
Answer: Managing highly customized orders that follow unique routing through various work centers
Job shop scheduling handles custom orders where each job may have a different sequence of operations through shared machines.
What does EOQ stand for in inventory management?
Answer: Economic Order Quantity
Economic Order Quantity is the optimal order size that minimizes total inventory holding and ordering costs.
A supplier scorecard is primarily used to:
Answer: Measure and track supplier performance across quality, delivery, and cost metrics
Supplier scorecards provide objective, data-driven performance ratings to manage relationships and drive supplier improvement.
An OSHA 'willful violation' is defined as one where:
Answer: The employer intentionally disregarded the law or showed plain indifference to worker safety
Willful violations carry the highest OSHA penalties and occur when an employer knowingly allows a hazardous condition to exist.
What is the purpose of Gauge R&R studies?
Answer: Assess measurement system variation due to repeatability and reproducibility
Gauge R&R evaluates how much of total variation comes from the measurement system versus the actual parts.
Which maintenance strategy typically results in the HIGHEST unplanned downtime costs?
Answer: Reactive (breakdown) maintenance
Reactive maintenance waits until equipment fails, resulting in unplanned downtime, emergency repair costs, potential secondary damage, and lost production.
What is 'heijunka' in lean manufacturing?
Answer: Production leveling to smooth out demand variation
Heijunka is the practice of leveling production volume and mix over time to reduce variability and waste.
What does NFPA 70E address in industrial facilities?
Answer: Electrical safety in the workplace including arc flash hazards
NFPA 70E provides requirements for safe work practices to protect workers from electrical hazards including arc flash and shock.
A Six Sigma process has a defect rate of approximately:
Answer: 3.4 defects per million opportunities
Six Sigma quality corresponds to no more than 3.4 defects per million opportunities (DPMO), representing near-perfect quality.
A 'pull system' in lean manufacturing means:
Answer: Production is triggered by actual customer demand
In a pull system, downstream demand signals upstream processes to produce, preventing overproduction.
What is a hypothesis test used for in Six Sigma projects?
Answer: Statistically determining whether observed differences between groups are real or due to chance
Hypothesis tests (like t-tests, ANOVA) validate whether process changes or differences are statistically significant.
What is cross-docking in logistics?
Answer: Transferring products directly from inbound to outbound transport with minimal storage time
Cross-docking minimizes warehouse storage by moving goods directly from receiving docks to outbound shipping docks.
What is a maintenance work order primarily used for?
Answer: Documenting, authorizing, and tracking specific maintenance tasks
A maintenance work order documents, authorizes, and tracks specific maintenance tasks, including labor hours, parts used, and task completion status.
In manufacturing maintenance, what does a Pareto analysis help identify?
Answer: The 20% of failure causes responsible for 80% of downtime
Pareto analysis identifies the vital few causes (roughly 20%) that account for the majority (roughly 80%) of equipment failures or downtime, allowing teams to prioritize corrective actions.
OSHA requires employers to record work-related injuries on which form?
Answer: OSHA 300 Log
The OSHA 300 Log of Work-Related Injuries and Illnesses must be maintained by most employers with 10 or more employees.