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Which statement about Lean implementation is false? A. When Lean and Six Sigma are combined the results are powerful. B. Lean minimizes customer value and maximizes waste. C. Lean promotes shorter cycle times, faster process times, and higher quality. D. Lean implementation is appropriate for office and service organizations. - ansB. Lean minimizes customer value and maximizes waste. DSub-optimization... A. Occurs when each individual function runs at peak performance without considering other functions or needs. B. Describes allowing sub-par performance of the supply chain. C. Considers not improving the entire process across the value stream to meet customer requirements - ansA. Occurs when each individual function runs at peak performance without considering other functions or needs. Lean Goals can be achieved by which of the following? A. Decreasing waiting time by implementing a push system B. Instituting incoming inspection C. Adding more non value-added activities D. Reducing waste by using techniques like 5S - ansD. Reducing waste by using techniques like 5S A Product Family refers to a group of products that go through the same or similar process steps, with similar process times and demand rates. How much of the same processing steps are usually shared? A. 100% B. At least 20% C. At least 80% D. At least 50% - ansC. At least 80% Which of the following will enable will enable flow? A. Supervising people B. Implementing a new inventory management system C. Eliminating sources of waste D. Reducing the number of your suppliers - ansC. Eliminating sources of waste In comparing Lean principles to Six Sigma principles, which of these statements is false? A. Six Sigma principles are problem-focused B. Six Sigma focuses on improving value streams C. Lean is focused on process flow
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D. Lean uses visuals to understand the process flow - ansB. Six Sigma focuses on improving value streams Which of the following roles often serves as the resource for removing roadblocks and resistance? A. Kaizen Team Leader B. Deployment Champion C. Kaizen Team Members D. Lean Leader - ansB. Deployment Champion When implementing Lean which of the following creates value for the customer? A. By implementing a Push system B. By implementing faster cycle times for non value-added process steps C. By identifying the Current Value Streams in your company D. Giving the customer what they need, when needed, and of the quantity needed - ansD. Giving the customer what they need, when needed, and of the quantity needed A Kaizen Event... A. Is typically carried out over a period of a year or two. B. Is designed to produce rapid results. C. Implements improvements to the entire value stream at the same time. D. Comes from the Japanese word "Kaizen" meaning "the place where the truth can be found." - ansB. Is designed to produce rapid results Who is responsible for the sponsorship and commitment of an organization to the Lean Methodology? A. Kaizen Team Leader B. Executive Champion C. Lean Leader D. Project Champion - ansB. Executive Champion Which factor should be considered when selecting improvement projects? A. Order of project submittal B. The impact on the Human Resources department C. Alignment with business strategy and goals D. How success will be rewarded - ansC. Alignment with business strategy and goals Which term describes the Six Sigma Methodology used for process improvement? A. Process Problem Improvement (PPI) B. Define, Measure, Analyze, Improve, Control (DMAIC) C. Process Quality Management and Improvement (PQMI)
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D. Focuses only on statistical measurement - ansC. Reduces variation and eliminates defects Which term can be used to measure the capability of a process? A. Defects per Million Opportunities (DPMO) B. Process Quality C. Just in Time (JIT) D. Design of Experiments (DOE) - ansA. Defects per Million Opportunities (DPMO) In which stage of the Six Sigma Methodology are the customer's requirements identified? A. Improve B. Analyze C. Define D. Control - ansC. Define Six Sigma has been described as a commitment to your customers, a statistical measurement of processes, and which of the following? A. A faddish theoretical method of quality management B. A way to increase variation C. A method to speed up the process D. A management framework for thinking about process economics, quality, and customers - ansD. A management framework for thinking about process economics, quality, and customers When starting a typical office improvement project, the improvement team will often find that transactional processes are... A. better on second shift than on first shift due to less interruptions from handling customer inquiries. B. well defined or documented. As a result it is often easy to define defects or errors. C. running at peak efficiency and producing zero defects. D. not very well defined or documented. As a result it is often difficult to define defects or errors. - ansD. not very well defined or documented. As a result it is often difficult to define defects or errors. Which Lean tool is useful in mapping the flow of the information or product through the office process? A. SIPOC Diagram B. Future State Value Stream Map C. Spaghetti Diagram D. Swim Lane Diagram - ansC. Spaghetti Diagram What is the basic difference in detecting waste in manufacturing and transactional environments?
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A. Manufacturing waste is harder to quantify. B. Office output is often intangible and can take the form of information flow. C. In manufacturing it takes a SME to find waste and in the office it doesn't. D. There are no differences; waste is detected in the same manner regardless of environment.
- ansB. Office output is often intangible and can take the form of information flow. Sub-optimization is likely to occur when departments or functions are centered around.... A. making deliveries. B. the customer. C. individual organizational goals. D. the flow of information. - ansC. individual organizational goals. What difficulty is often experienced while implementing Lean within a typical office environment? A. Lack of potential solutions being identified B. Lack of sufficient waste for action to be taken upon C. Personnel do not welcome change. They are happy the way things are. D. Lack of business objectives - ansC. Personnel do not welcome change. They are happy the way things are. Lean transactional processes can be broken down into two primary functions. What are those two functions? A. Production, Accounts Payable B. Logistics, Management C. Human Resources, Finance D. Office, Service - ansD. Office, Service How is 5S/6S utilized during Lean improvement activities? A. Guides organizations to create and maintain an organized, clean and safe work environment as a foundation for achieving Lean B. Highlights the cost impact of adding queuing locations within the office area C. Used strictly in a manufacturing environment and is not generally utilized in any office or service Lean improvement activity D. Categorizes process steps into value-added and non value-added activities - ansA. Guides organizations to create and maintain an organized, clean and safe work environment as a foundation for achieving Lean Which of the following is NOT among the three key techniques for improving a business transactional process? A. Eliminate redundancy such as requirements for multiple reviews and approvals, or duplicate copies B. Implementing the Current Value Stream map
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A. Lack of potential solutions being identified B. Lack of sufficient waste for action to be taken upon C. Personnel do not welcome change. They are happy the way things are. D. Lack of business objectives - ansC. Personnel do not welcome change. They are happy the way things are. Which Lean tool is useful in mapping the flow of the information or product through the office process? A. SIPOC Diagram B. Future State Value Stream Map C. Spaghetti Diagram D. Swim Lane Diagram - ansC. Spaghetti Diagram Which of the following is NOT among the three key techniques for improving a business transactional process? A. Eliminate redundancy such as requirements for multiple reviews and approvals, or duplicate copies B. Implementing the Current Value Stream map C. Eliminate bureaucracy and non-essential processing, especially if it is not an absolute requirement that can be justified D. Complete a Value Added Analysis to determine if work activity adds value to the service provided - ansB. Implementing the Current Value Stream map In a theory of constraints context, policies, rules, measurements, and training are examples of... A. non-physical constraints. B. organizational imperatives. C. physical constraints. D. things needing to be buffered. - ansA. non-physical constraints. The rope in a theory of constraints system... A. controls material release duration in order to keep the buffer at a certain level. B. authorizes production. C. protects the pace. D. sets the pace. - ansA. controls material release duration in order to keep the buffer at a certain level. A TOC tool which is used to examine the cause and effect logic behind the current situation and which helps determine why that situation is different from its preferred state is the... A. intermediate objective map. B. current reality tree.
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C. prerequisite tree. D. future reality tree. - ansB. current reality tree. The drum in a theory of constraints system... A. enforces the pace. B. authorizes production. C. protects the pace. D. sets the pace. - ansD. sets the pace. In the theory of constraints, the pace of a bottleneck production operation is controlled by the pace of... A. the previous (upstream) operation. B. the next (downstream) operation. C. the weakest link. D. another non bottleneck operation. - ansC. the weakest link. One of the key ideas in Goldratt's theory of constraints is to maximize system performance by... A. balancing the production line, i.e., equal capacity at each operation. B. strengthening the weakest link the chain. C. maximizing production at each operation. D. minimizing the buffer. - ansB. strengthening the weakest link the chain. A person waiting until the last possible moment before fully applying themselves to completing a task is an example of... A. multitasking. B. Parkinson's Law. C. suboptimization. D. Student Syndrome. - ansD. Student Syndrome. The buffer in a theory of constraints system... A. enforces the pace. B. authorizes production. C. protects the critical chain. D. sets the pace. - ansC. protects the critical chain. In a theory of constraints system, throughput of the process is determined by... A. the system constraint, or weak link. B. the money flowing out of the system. C. the money in the system. D. customer demand. - ansA. the system constraint, or weak link.
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C. Level Three process map. D. Level Four process map. - ansA. Level One process map. In a process map the oval is used to... A. denote a process task. B. denote a decision point. C. identify defects in the process. D. indicate a starting or stopping point. - ansD. indicate a starting or stopping point. All of the following should be included in a process map except... A. available data, such as sigma level, COPQ, and defect rate. B. cause and effect relationships. C. the sequence of activities and decision points. D. rework loops. - ansB. cause and effect relationships. When developing a process map... A. use standard operating procedures to validate the process. B. document only what you know of the process. C. "walk the process" in order to develop an accurate representation. D. document only what the subject matter expert told you to ensure accuracy. - ansC. "walk the process" in order to develop an accurate representation. Before beginning the actual task of mapping a process it is important to... A. define the number of decision points in the process. B. clearly define the boundaries of the process. C. identify all the inputs to each process step. D. identify which decision points lead to a previous step in the process. - ansB. clearly define the boundaries of the process. Clearly defining the boundaries of a process... A. helps define customer requirements. B. helps prevent "scope creep." C. drives automation improvements. D. allows for management techniques to take effect. - ansB. helps prevent "scope creep." Which one of the following symbols denotes a decision point on a process map? A. Rectangle B. Diamond C. Oval D. Arrow - ansB. Diamond When creating a process map, the purpose of a walkthrough is to...
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A. check on the best time to set up interviews. B. understand who is working on value-added activities and who is not. C. collect audit artifacts and documentation samples to check against the master database. D. understand what is actually being done and why it is being done. - ansD. understand what is actually being done and why it is being done. The people needed to create a process map are: A. Consultants B. People independent of the process. C. Quality Control Experts. D. People involved in the process. - ansD. People involved in the process. Which of the following is an example of Wasted Human Potential? A. Lack of proper tools, equipment, or supplies to properly perform the task B. An environment that builds morale C. Typographical errors D. Including everyone who performs a task in the improvement of that task - ansA. Lack of proper tools, equipment, or supplies to properly perform the task What are the primary benefits of eliminating or significantly reducing waste in an organization? A. There are no tangible benefits to the organization B. Reducing costs and increasing flexibility C. Leadership can raise the selling price of their products or service D. The customer is willing to pay more for the product or service - ansB. Reducing costs and increasing flexibility Which of the following is the best description of "waste" in Lean methodology? A. Low-cost / no-cost solutions that provide only a small amount of value to a product or service B. Small batch sizes that keep inventory/work moving through the system but are not as easy for batch operators as a large batch would be C. Any process activity that does not add value to the transformation of materials or information into a product or service delivered to a customer D. Utilizing a Pull system based on actual consumption doesn't prepare adequately for the "just in case" scenarios that inevitably arise. - ansC. Any process activity that does not add value to the transformation of materials or information into a product or service delivered to a customer Which of the following is considered waste? A. Storing extra items in a warehouse B. Properly training operators
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D. The steps of a good root cause investigation - ansB. The three critical components of a good A The Red Tag event is part of which phase of 5S? A. Sort B. Set in Order C. Standardize D. Sustain E. Shine - ansA. Sort In a 5S effort, what must be done before cleaning the work environment? A. Generate audit checklists B. Ensure the improvements are put in place as best practices C. Organize and arrange the items in the work place D. Maintain the improvements over time - ansC. Organize and arrange the items in the work place Which Lean technique is commonly used with 5S in the Set in Order phase? A. Flow and pull B. Changeover reduction C. Visual controls D. Error Proofing - ansC. Visual controls When Safety is included as the sixth S in a 5S effort, which of the following is an additional activity that may be included in the implementation? A. Remove visual display boards B. Properly store personal protective equipment C. Put in place audit procedure D. Institute changeover reduction - ansB. Properly store personal protective equipment In the 5S process, visual controls that communicate how work should be done are implement in which phase? A. Sort B. Shine C. Set in Order D. Standardize E. Sustain - ansC. Set in Order What is the final phase of 5S? A. Sustain B. Shine C. Set in Order
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D. Standardize E. Sort - ansA. Sustain Which of the 5S/6S phases is being described by the following actions? Be sure file cabinets are not overloaded. Make sure that tripping hazards are eliminated. Keep emergency and medical supplies in clearly marked locations. A. Setup B. Security C. Satisfaction D. Safety - ansD. Safety Which of the following is a benefit of the 5S phase Sustain? A. Improves productivity and workplace flexibility B. Places required tools and materials needed for the process step in easy reach of the worker C. Improves overall work environment D. Improves employee morale and builds self-discipline within the business culture to ensure 5S activities become habit - ansD. Improves employee morale and builds self-discipline within the business culture to ensure 5S activities become habit Which of the following is the correct order of the 5S phases? A. Set in Order, Shine, Sort, Standardize, Sustain B. Sort, Set in Order, Shine, Standardize, Sustain C. Shine, Sort, Set in Order, Standardize, Sustain D. Standardize, Sort, Set in Order, Shine, Sustain - ansB. Sort, Set in Order, Shine, Standardize, Sustain Which Visual Management visual cue is intended to communicate information, but not that an immediate reaction is required? A. Visual Display B. Visual Condition C. Visual Control D. Visual Target - ansA. Visual Display To prepare the work environment to contain visual information and controls, which one of the following Lean techniques is most widely used? A. Value stream mapping B. 5S C. Kaizen D. Mistake proofing - ansB. 5S Which of the following is an example of a self-explaining Visual Management technique? A. Pictures that describe the work that is taking place
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Which Phase of Standard Work identifies the "best" approach to each work step, and standardizes that approach? A. Develop Standard Work B. Implement C. Establish Goals D. Analyze Current Process - ansA. Develop Standard Work In order to build stability in processes and create a foundation for improvement, Standard Work defines work activities for... A. suppliers and customers. B. content, timing, sequence, and outcome. C. sort, set in order, shine, standardize, and sustain. D. visual controls, displays, and metrics. - ansB. content, timing, sequence, and outcome. In which phase of implementing Standard Work is a communication plan for leadership and team members developed while making sure to set clear expectations for roles and responsibilities? A. Establish Goals B. Analyze Current Process C. Implement D. Develop Standard Work - ansC. Implement The four phases of Standard Work are: A. Establish the Process, Analyze Goals, Develop Standard Work, Implement. B. Establish Standard Work, Analyze Current Process, Develop Goals, Implement. C. Establish Standards, Analyze Current Process, Develop Standard Work, Implement Goals. D. Establish Goals, Analyze Current Process, Develop Standard Work, Implement. - ansD. Establish Goals, Analyze Current Process, Develop Standard Work, Implement. In which phase of implementing Standard Work does the team set expectations for the amount of time it should take to complete each activity? A. Develop Standard Work B. Implement C. Establish Goals D. Analyze Current Process - ansC. Establish Goals Standard Work defines who, what, when and where work is to be performed. A. True B. False - ansA. True
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Which Lean concept guides companies to document the best way to utilize their people, equipment, and materials in order to create a work method that meets the needs of the customer with the least amount of waste possible? A. Standard Work B. Kaizen Event C. 5S D. Eight Wastes - ansA. Standard Work Which phase of implementing Standard Work observes work activities performed in multiple situations? A. Develop Standard Work B. Implement C. Establish Goals D. Analyze Current Process - ansD. Analyze Current Process Standard Work focuses on creating the... A. perfect way to perform work. B. best possible work method. C. way the Process Owners feel it should be done. D. way it was proposed for cost estimates. - ansB. best possible work method. Standard Work Sheets contain Timing, Outcome and what other key component? A. Current State Value Stream Map B. Work Sequence: the step-by-step order of operations C. Inventory on hand D. The annual or semi-annual review date - ansB. Work Sequence: the step-by-step order of operations An Error Proofing "alert".... A. prevents a failure from moving forward uncorrected. B. provides a signal that an error has occurred. C. shuts down the process completely when an abnormality has been detected. D. alerts management to visit the process. - ansB. provides a signal that an error has occurred. Error Proofing is a technique used to make failure or potential failure easy to detect or to.... A. prevent it from occurring. B. rework it. C. redesign it. D. eliminate it. - ansA. prevent it from occurring. An Error Proofing "control"....
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Workplace Design is best described as... A. reducing the time and cost of transitioning a process from producing one product to producing a different product. B. a process for creating a workspace to enhance value by minimizing travel distances, eliminating waste, reducing lead times, improving teamwork, and gaining flexibility. C. having suppliers and customers share floor space with your company. D. designing the workplace to minimize people-related costs. - ansB. a process for creating a workspace to enhance value by minimizing travel distances, eliminating waste, reducing lead times, improving teamwork, and gaining flexibility. Which Workplace Design outcome results from enabling work to move continuously from step to step, rather than requiring operations to stop and start? A. A flow and pull work area B. A cross-trained workforce C. A flexible workforce D. An optimized work environment - ansD. An optimized work environment Workplace Design relies on co-locating work processes to... A. enhance workspace utilization. B. accomplish zero inventory. C. increase ease of movement. D. improve communication and promote teamwork. - ansD. improve communication and promote teamwork. Which of the following concepts results in fewer opportunities for operator error, improved quality output, and higher overall efficiency? A. Takt Time B. Continuous Flow C. Production Scheduling D. Value-added Processing - ansB. Continuous Flow In a production factory that has successfully implemented a Pull System, which of the following typically occurs? A. Increased prices B. Adding inventory to cover demand C. Less inventory D. Higher defect rate - ansC. Less inventory The cellular environment and one-piece completion process of Continuous Flow enables organizations to identify and eliminate non value-adding activities that were previously hidden.
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A. True B. False - ansA. True How is a Pull System different from a Push systems? A. A Pull System relies on a forecast or open capacity. B. A Pull System is dependent on actual customer orders. C. The process must continuously produce product to the maximum capacity of the line. D. There is no real difference; a Pull System functions similarly to a Push system. - ansB. A Pull System is dependent on actual customer orders. When the term "Pull" is used in Lean thinking, who is ultimately doing the pulling? A. Downstream operations B. Takt Time C. Actual customer requests, orders, or consumption D. The cycle time - ansC. Actual customer requests, orders, or consumption What type of Kanban is used when one container of parts is to be moved to a production line or supermarket? A. Withdrawal Kanban B. One-card Kanban C. Kanban Square D. Two-card Kanban - ansA. Withdrawal Kanban To calculate the required inventory for Flow and Pull Systems, organizations use the equation... A. Over Stock plus Buffer Stock plus Safety Stock. B. Cycle Stock plus Buffer Stock plus Extra Stock. C. Cycle Stock plus Quality Stock plus Safety Stock. D. Cycle Stock plus Buffer Stock plus Safety Stock. - ansD. Cycle Stock plus Buffer Stock plus Safety Stock. In a Push System, works moves through the system based on... A. the customer. B. Cycle time. C. a forecast or open capacity. D. Takt Time. - ansC. a forecast or open capacity. Another term for continuous flow is.... A. one piece flow. B. non stop production. C. inspection free material. D. zero maintenance time. - ansA. one piece flow.
