A prevention cost is spent to do what?
A Inspect finished goods
B Repair failures
C Handle customer returns
D Avoid defects
Answer: D. Avoid defects. Prevention costs fund activities designed to prevent quality problems.
Appraisal costs are spent on what activity?
A Product redesign only
B Warranty repair
C Inspection and testing
D Scrap disposal
Answer: C. Inspection and testing. Appraisal costs measure or verify product and process conformance.
Internal failure costs occur before what event?
A Production start
B Supplier order
C Product design
D Customer delivery
Answer: D. Customer delivery. Scrap and rework discovered before shipment are internal failure costs.
External failure costs arise after what?
A Material receipt
B First operation
C Machine setup
D Customer delivery
Answer: D. Customer delivery. Warranty, returns and complaints are external failure costs.
Anthropometry provides data about human what?
A Machine capacity
B Material strength
C Product demand
D Body dimensions
Answer: D. Body dimensions. Anthropometric data describe human body measurements for workplace design.
A neutral working posture generally reduces what?
A Musculoskeletal strain
B Product quality
C Machine output
D Inventory cost
Answer: A. Musculoskeletal strain. Neutral postures reduce joint stress and risk of musculoskeletal injury.
RULA and REBA are tools for assessing what?
A Process capability
B Supplier quality
C Ergonomic posture risk
D Inventory age
Answer: C. Ergonomic posture risk. RULA and REBA evaluate postural risk in work tasks.
Industrial noise exposure is managed to protect what?
A Vision only
B Hearing
C Product finish
D Machine alignment
Answer: B. Hearing. Noise controls and hearing protection reduce risk of hearing loss.
Adequate task lighting helps reduce visual what?
A Machine wear
B Inventory loss
C Strain
D Material deformation
Answer: C. Strain. Suitable lighting improves visibility and reduces eye strain and error risk.
A basic risk score often combines likelihood and what?
A Cycle time
B Severity
C Inventory value
D Product mass
Answer: B. Severity. Risk ranking commonly considers likelihood of occurrence and consequence severity.
Personal protective equipment is a control used after what?
A All hazards eliminated
B No risk assessment
C Higher-level controls considered
D Production completed
Answer: C. Higher-level controls considered. PPE protects workers when hazards cannot be fully controlled by elimination or engineering measures.
A safety audit reviews hazards and what controls?
A Product features
B Supplier prices
C Machine colors
D Risk controls
Answer: D. Risk controls. Safety audits examine hazards, controls, procedures and compliance.
An accident frequency rate relates incidents to what exposure?
A Work hours
B Product demand
C Machine capacity
D Inventory value
Answer: A. Work hours. Frequency rates normalize incidents by hours worked or another exposure measure.
A workstation should place frequently used tools where?
A Behind the operator
B Above shoulder height
C Outside the cell
D Within easy reach
Answer: D. Within easy reach. Convenient reach zones reduce unnecessary movement and awkward posture.
Visual management makes performance and abnormalities what?
A Hidden
B More variable
C Visible
D Impossible to compare
Answer: C. Visible. Visual systems show status, standards and abnormal conditions at the workplace.
A job enlargement increases what?
A Responsibility level only
B Task variety at same level
C Machine capacity
D Customer demand
Answer: B. Task variety at same level. Job enlargement adds tasks of similar responsibility to broaden the role.
Job enrichment increases what?
A Autonomy and responsibility
B Repetitive motion
C Inventory buffer
D Inspection frequency
Answer: A. Autonomy and responsibility. Job enrichment adds planning, decision-making and responsibility.
A piece-rate incentive links pay to what?
A Machine color
B Output quantity
C Supplier count
D Product dimensions
Answer: B. Output quantity. Piece-rate systems reward workers based on units produced, subject to quality safeguards.
A balanced scorecard combines financial and what measures?
A Only inventory counts
B Nonfinancial performance
C Only supplier ratings
D Only machine speeds
Answer: B. Nonfinancial performance. Balanced scorecards include financial, customer, process and learning perspectives.
Carbon footprint measures greenhouse-gas emissions in what units?
A CO2 equivalent
B Kilowatt-hours only
C Cubic metres only
D Kilograms of steel
Answer: A. CO2 equivalent. A carbon footprint aggregates greenhouse gases as carbon-dioxide equivalent.
Energy efficiency is useful output divided by what?
A Energy input
B Machine time
C Material mass
D Worker count
Answer: A. Energy input. Energy efficiency compares useful output with energy consumed.
A sustainability assessment considers environmental, social and what?
A Tool geometry
B Economic impacts
C Surface finish
D Machine color
Answer: B. Economic impacts. Sustainability decisions consider environmental, social and economic dimensions.
A green manufacturing program aims to reduce waste and what?
A Product quality
B Worker safety
C Resource consumption
D Customer satisfaction
Answer: C. Resource consumption. Green manufacturing reduces material, energy and environmental impacts.
A suggestion system collects improvement ideas from what source?
A Employees and teams
B Machines only
C Customers only
D Suppliers only
Answer: A. Employees and teams. Frontline employees often identify practical opportunities to improve work.
A standard operating procedure helps ensure what?
A Consistent work method
B Maximum inventory
C Unplanned variation
D No training
Answer: A. Consistent work method. SOPs document repeatable methods and required controls.