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Lean Bronze exam (
questions and answers)
In lean thinking, value is created by the producer but can only be defined by the: Ultimate End User Gemba in a service company is where: customers come into contact with services offered The best way to handle low-volume, low-frequency orders with high-demand variation is to: supply product as it is demanded Defining value and making it flow typically leads to organization of production according to: product families Organizations commonly add which of the following metric categories to PQCD to measure value to the customer? Safety Value is defined as: What the customer is willing to pay for Which term denotes the voluntary alliance of all interested parties to oversee the entire value stream and eliminate all forms of waste? Lean enterprise When looking at a value stream to create and deliver value to customers, it is necessary to go beyond the confines of a company to include upstream suppliers. When this is done, what typically is the immediate discovery? Duplicate or repetitive processes
The reason and motivation behind process measurements in general is measuring: what you want to improve Inventory for a "non-lean" company is normally considered a (an)__________ while inventory for a lean company is viewed as _________. asset; waste SMART goals should be set collaboratively with __________, having the __________ in mind in order to be most effective. employee; customer When lead time is reduced, what measure typically increases? Inventory Turns If the countermeasures implemented from doing your A3 practical problem solving exercise fail to produce the expected results, you should: Revisit your A3 and identify other potential countermeasures Which of the following is the most important when running a process? Quality Which is most important when building your "corporate quality culture"? Problems are identified and fixed Your management decisions should be based on which of the following: A long-term philosophy Kanbans are a good example of: Visual management According to lean, problems are: Opportunities for improvement What does TAKT time measure? demand frequency
Why is an ISO quality program important? It standardizes the way the work is done. Calculate the production capacity using 420 minutes per shift, a process time of 15 minutes per unit, and downtime of 20 minutes. 26.6 units Which of these are not part of a 5S system? Solve Which of the following is NOT a path to poka-yoke? Deviations from the mean When the processes are disconnected and conveyance distances are long, which of the following is the proper method convey parts? Fixed time and variable quantity conveyance Which of the following is not a pillar of gemba kaizen in the commonsense, low-cost approach to improvement according to Masaaki Imai? Quality function deployment In order to form a view in the minds of value stream managers of what perfection would be, which of the following is NOT a principle he/she needs to apply? Push production Flow Which is not a sign of Muri? Operating waiting for work Which item is not thought of as a key feature of standards? Limits free thinking Why do we seek perfection on our lean continuous improvement journey? Seeking perfection causes us to look for opportunities not seen if only focused on minor improvement
An activity which does not add value is called: Muda Which of the following is NOT one of the 4Ms at Toyota to ensure stability? Measurement Which of the following is used to control production where continuous flow does not extend upstream? Supermarket To achieve stability, one must occasionally implement: Non-lean actions such as increasing buffers The principle of Jidoka does not include which of the following items? Final inspections Who was considered the first to realize the potential of flow? Henry Ford Standards are meant to: Continually change Which of the following would have the lowest defect rate? Two-man team (one do and one check, then reverse roles) The Japanese word "ji-do-ka" is comprised of three Chinese characters, where "do" refers to: Motion Which of the following is NOT an activity of standardization? Heijunka Process A has 35 minutes of processing time and 63 minutes of retention time. What is the lead time? 98
Root cause The core activity of management is: PDCA Which of the following terms describes lots of commotion, and many isolated victories in the great war against muda? Kamikaze kaizen Which of the following 5S terms means self-discipline? Shitsuke International certification programs like ISO9001 place emphasis on: standardization of key processes and continual improvement In TPM, basic maintenance work is assigned to: production teams Which is the following people are noted for SMED? Shigeo Shingo The basis, or starting point, for improvement of a process is the: current standard work In total productive maintenance, the basic maintenance work- such as inspection, cleaning and lubricating are assigned to: production team members A lean manager's job is to practice and teach which of the following? PDCA Which of the following lean principles can be used to identify and prioritize projects for continuous improvement? Pull ___________ and TPM must be both put in place and working first before JIT can be introduced.
Total quality control What statement best describes the reason for and intent of standard work? Do the work as prescribed and find ways to improve it Among the six big losses that downgrade machine effectiveness, which is idling and minor stoppages ISO 9001 certification benefited Infotec because it provided: an official review of the standards to keep trying to do a better job 1.1 Principles of Cultural Enablers Per the principles of the Toyota Production System (TPS), which of the following does mutual respect between company and its employees mean? Employment security 1.1 Cultural Enablers Which of the following is a good example of a paradox and a key principle of the Toyota Production System (TPS)? Stop production so that production never has to stop Which of the following presentation items in the Toyota Production System is not a good example of the visual management as a theater in which ship floor problems can be made visible? Production report review at end of shift Which of the following is not a routine training for Kaizen circle activity at Toyota? Time management Kaizen events do not primarily focus on which of the following? Headcount reduction Suggestion programs generate identifiable improvements in tangible and those that do not have direct, dollar, time or space savings. Which of the following is a non-tangible improvement? potential for spill eliminated
Which of the following is a mantra that represents teamwork at Toyota? All for one and one for all Which of the following means information sharing across the plant, plus sharing common issues and countermeasures? Yokoten What is the "Kosu" a foreman must work to reduce, given the following details: five people, eight hours producing 100 units?
In lean principles, driving the behavior of the front-line employees supercedes the needs of providing information to management for making a decision. Which of the following represents this philosophy best? Poka-yoke Which of the following are cultural values that facilitate an active suggestion system? a) Openness and mutual trust b) Teamwork c) Customer Focus a & c only a & b only a, b, & c b & c only a, b, & c In an organization a generic term "concrete head" is used to describe a person who: Is limited by the current paradigms and refuses to change Which statement is the best example of a learning organization? Acceptance of trial and error based on knowledge and experience of the daily work In building a lean culture, which of the following is least in importance?
Investing a lot of capital in acquiring or developing technology Sustaining a lean culture requires that: (Womack & Jones) Traditional roles and functions within an organization must change What best describes "organizational culture"? The day-to-day experiences of the team members The ones who have gone before emphasizes deeper thinking by the model of: Self-awareness and endless practice Value is only meaningful when expressed in terms of a specific product or service that is created from whose viewpoint? Customer Which of the following is NOT one of the basic rules of practicing Kaizen in gemba? Spend your money on Kaizen Lean production as a path involves: Respect for people Which of the following is a critical element for the success of a lean enterprise? Top management commitment Place the following Golden Rules of Gemba Management in the correct order: Find the root cause Check the gembutsu Standardize to prevent recurrence When a problem arises, go to gemba first Take temporary countermeasures on the spot 4,1,2,5, 4,2,5,1, 5,1,2,4, 2,4,1,5,
Which of the following is NOT a criterion for an idea system used in lean? An idea system must: Be a hassle-free process. When measuring internal quality in lean, non-value added activities often can by identified by: Speaking to external customers. In lean, scientific thinking is used to: Foster a cycle of continuous improvement. Which of the following is NOT a workplace safety measure used in lean? Adopting and adhering to green practices. In lean, gauging process performance is most crucial for: Forming metrics. Effective suggestion programs: Encourage idea generation and reward team member initiative. Which statement about benchmarking is true? A generic cross-industry study involves forming a cross-functional team to compare various problem areas and their countermeasures. Which of the following is NOT a means of ensuring flexible responsiveness? Examining the percentage of total available demand for a product or service. Which statement is true about total productive maintenance? In lean, the main goal of TPM is to: Maximize equipment usefulness by continuously caring for equipment Which statement is true about metrics used in lean? When applied to lean, a metric becomes: The unit of measure for processes. Which of the following is NOT a means of measuring external quality in lean? Examining the percentage of total available demand for a product or service.
Which of the following is NOT a criterion for an idea system used in lean? An idea system must: Center around team-based activities. JIT production requires: Good process flow. Total Quality Control (TQC) is an integrated effort aimed at: Driving continuous improvement at all levels. A focused project that involves a cross-functional team working on a targeted problem area and implementing countermeasures to the problem is a/an: Kaizen event A Gemba walk is BEST described as a means of: Gathering first-hand information on the status of a production process. Which statement is true about reducing cost? Focusing primarily on reducing cost typically: Helps in the creation of metrics. Which of the following environmental safety measures are NOT used in lean? Adopting and adhering to green practices. The main goals of ergonomics are: Optimizing employee comfort and reducing employee fatigue. Ensuring that a process can meet takt time often requires: Line balancing. In lean, the BEST way to determine if improvement has taken place is through: Metrics tracked over time. A setup reduction method that reduces setups to less than 10 minutes is called: SMED.
In lean, the BEST way to determine if improvement has taken place is through: Metrics tracked over time. The seven forms of waste include overproduction, idle time, unnecessary transport, over processing, excess inventories, unnecessary motion, and: Defects. If you attempt to make 500 units and 450 of those units are good, your first pass yield is: 90% Cash flow is money that: Is available for the company to reinvest in other resources. Which section of the balanced scorecard tracks the development of the company's employees and of the company itself? Learning. For a production facility working five days per week (one 8 hour shift with three ten minute breaks), the customer demand is 2700 units per week. What is the takt time this facility should produce to? One unit every 10 seconds. A strategic management and planning tool that is used to track information that is not covered in traditional financial reporting systems is the: Balanced scorecard. A setup reduction method that reduces setups to less than 10 minutes is called: SMED. Which type of inventory primarily is used to address a SUDDEN increase in demand that exceeds production capacity? Buffer stock. Critical to quality standards reflect what is important to the:
Customer. Which of the following lean tools uses clustered points to determine if there is a relationship between two variables? A scatter diagram. A production method that reduces defects and significantly reduces inventory and the wastes associated with it, such as managing, moving, or storing extra parts, is called: Continuous process improvement. A future state value stream map shows: What is the best arrangement of processes that can be accomplished in a reasonable time period. Continuous process improvement is BEST defined as: An ongoing effort to eliminate waste, make processes more effective, and create more value for customers. A value stream map icon that represents inventory kept on hand to protect the stream from downtime is: The safety stock icon.
