Lean Management Certification Test Answers

Ques : The various kinds of Kanban include:
Ans  :  Supplier Kanban
           In-Factory Kanban
           Customer Kanban

Ques :  What are the three C's essential for Supply Chain Management?
Ans  : Communication
          Customer Satisfaction

Ques : Why did Ford begin to lose its hold in the market?
Ans  : There was a sudden rise in the product variety
          Annual changes in models and multiple colors and options suited the Ford factories

Ques : Which of the following is necessary for the success of Lean implementation?
Ans  : There needs to be a total cultural change in the organization
          The value stream has to be mapped

Ques : Which of the following are true regarding value stream mapping?
Ans  : It is a tool to look at how value flows into and through a process to the customer
          It helps to locate the wastes in the value chain

Ques : Which principle of Lean makes use of spaghetti charts?
Ans  : Value Stream

Ques : Where was the first TPM conference held?
Ans  : The United States

Ques :  Pull System is another name for ______.
Ans  : Kanban

Ques : Which method helps in the optimization of machinery?
Ans  : Total Productive Maintenance

Ques : Cycle Time Reduction is:
Ans  :  the time needed to complete a task within a process

Ques : State whether true or false:

Applying Lean to Supply Chain Management helps to certify the suppliers.
Ans  : True

Ques :  Which of these need not be a feature of Lean metrics?
Ans  :  They should be made keeping in mind the goals of the competitor

Ques : Which of the following losses does not eliminate TPM?
Ans  : Quality losses

Ques : What is the main reason for the occurrence of waste?
Ans  : Inventory

Ques : Which of the following is not done by poka-yoke?
Ans  :     It helps in the optimization of resources in an organization

Ques : What is the function of SMED?
Ans  :  To reduce the changeover in a process

Ques : Who is known as the "father of scientific management"?
Ans  : Shigeo Shingo

Ques :Whom did the four locations on the large board of the Beer Game not represent?
Ans  : The Customer

Ques : Which of the following is not a Lean Tool?
Ans  :Design of Experiments

Ques : Which of the following cannot be considered a waste?
Ans  : Skilled plant workers

Ques : What is the formula to calculate cycle time?
Ans  :  Available work time / Customer required volume

Ques : What does Kanban mean?
Ans  : A card-signal

Ques : For any company to reach a 'level 6' sigma, there should only be _______ defects per million opportunities.
Ans  : 3.4

Ques : What is the similarity between Lean and Six Sigma?
Ans  : Both deliver higher quality of service with greater speed

Ques : Synchronous Flow Manufacturing plans inventory around:
Ans  :  Capacity Constraint Resources

Ques :  The data that does not need to be communicated in a Visual Factory environment are:
Ans  :  work instructions

Ques : What is also known as 'law zero' in Lean Six Sigma?
Ans  : The Law of Waste

Ques : Which of the following is not synonymous with Lean Manufacturing?
Ans  :  World Class Manufacturing

Ques : Who introduced the concept of mass production?
Ans  : Henry Ford

Ques : What is Takt Time?
Ans  : None of the above

Ques : Which of the following is true with regard to Synchronized Flow Manufacturing?
Ans  : It improves the manufacturing system by setting off an increase in operating costs

Ques :  A flexible process is:
Ans  : one which can be reconfigured to give different output for different customer demands

Ques : Which of these features does not describe the features of the Ford system?
Ans  :  Materials do not go from "dock to stock" but from dock to the factory floor

Ques : Who among the following is involved in the implementation of Kaizen?
Ans  : Workers

Ques : How many wastes are identified by Lean?
Ans  : 8

Ques : What is not an advantage of SMED?
Ans  :  It increases elasticity in the process

Ques : Six Sigma processes are implemented by organizations to reduce __________
Ans  : defects in their processes

Ques : What is the main function of Lean?
Ans  :  Eliminating muda

Ques : According to the Theory of Constraints, ______________________.
Ans  : every process or system has a constraint that acts as an impediment in attaining more of its goal

Ques :  _________ means to clear the work area.
Ans  : Shine

Ques :  What are the advantages of applying Lean to a supply chain?
Ans  : None of the above

Ques :  State whether true or false:

Single unit manufacturing cannot be approximated to continuous flow manufacturing.
Ans  : False