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1. A company produces 2 products A and B.

The weekly demand for A is 200 pieces, the


weekly demand for B is 300 pieces. If the company uses Heijunka, how should production
for A and B be performed, using 5 days of production per week?
Select one:
a. First we produce 200 pieces of A on the first 2 days of the week and then we produce
300 pieces of B during the last 3 days of the week
b. We produce 40 pieces of A and 60 pieces of B every day
c. We produce the same total number of A and B every day, although the individual
quantities of A and B may change from day to day.
2. Andons are ____________________
Select one:
a. A way to signal that a problem has occurred

b. A method to find the root cause of a problem

c. Neither of the above

3. Generally efforts at implementing 5S fail because _______________


Select one:
a. 5S requires people to change their habits
b. Management does not measure performance of 5S
c. Lack of understanding of the benefits of 5s
d. All of the above
e. None of the above

4. Generally how long does it take to complete the implementation of 5S?


Select one:
a. About one month
b. About 3 months
c. About 1 year

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d. Never. It is an ongoing process.

5. Generally speaking, __________ leads to __________ which leads to _________


Select one:
a. Mura, Muri, Muda
b. Muri, Muda, Mura
c. Muda, Muri, Mura
d. Muda, Mura, Muri

6. If the takt time is greater than the machine cycle time it means that the demand cannot be
met using that machine.
Select one:
a. True

b. False

7. In Toyota, if the number of andon pulls are fewer than what has been planned for,
management interprets it is an indication that __________
Select one:
a. The system is working well
b. The people are not pushing the system enough
c. That the andon chord is not functioning

8. In Value Stream Mapping, it is very important to gather accurate inventory data


Select one:
a. True

b. False

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9. In Value Stream Mapping, the inventory between 2 processes, A and B, has been found to
be 1800 pieces. The cycle time for A is 1 minute, The cycle time for B is 30 seconds. The
daily demand is 600 pieces. Assume there are 27000 seconds of working time per day.
How many days of inventory exist between A and B?
Select one:
a. Between 2 and 3 days
b. 8 days
c. 4 days
d. None of the above

10. In which of the following is scheduling easier?


Select one:
a. Product type layouts
b. Process type layouts
c. It is roughly the same in both

11. It is important to execute the 5 Ss in sequence, i.e., the first S followed by the second S,
and so on.
Select one:
a. True
b. False

12. Machine cells are best suited for


Select one:
a. Very high volume products

b. Very low volume products

c. Medium volume products

13. Poka yoke is a __________________


Select one:

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a. Way to automate a process to eliminate errors

b. A method to prevent errors from being made

c. A countermeasure for problems

14. Red tagging is used in


Select one:
a. The 1st S

b. In Visual Management

c. In Jidoka

d. In Poka Yoke

15. Result orientation is generally found in __________, while process orientation is generally
found in ____________
Select one:
a. Western organizations, Japanese organizations

b. Japanese organizations, Western organizations

16. Standardization _________________


Select one:
a. Is required only before an improvement
b. Is required only after an improvement
c. Is required both before and after an improvement
d. Has no relationship with improvement activities

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17. The inspiration for Kanban originally came from _________________


Select one:
a. A grocery store in the U.S.

b. A small manufacturing plant in Iowa

c. A bank

d. None of the above

18. The month-end phenomenon when a large part of the production for the month is
completed in the last 10 days, is an example of which of the following?
Select one:
a. Mura
b. Muri

c. Muda
d. None of the above

19. The production capacity chart is used in _____________


Select one:
a. Standard work

b. Jidoka

c. Poka Yoke

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d. None of the above

20. The reason why companies carry inventory is _________________


Select one:
a. Absenteeism

b. Long setup times

c. Poor quality

d. All of the above

e. None of the above

21. There are two equations given below: 1. Selling price = Cost of manufacturing and
distribution + Profit margin 2. Profit margin = Selling price cost of manufacturing and
distribution. Select the one answer most applicable to the above equations:
Select one:
a. There is no difference in the equations

b. The difference in the interpretation of equations forms the basis for TPS/Lean

c. One of the equations is incorrect

d. None of the above

22. Under craft manufacturing, we had _________.


Select one:
a. Part interchangeability

b. Low cost

c. Job satisfaction

d. Short lead time

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23. Value of an item is most closely associated with


Select one:
a. What it cost the manufacturer to produce it

b. The selling price of the item

c. The utility seen by the customer

d. None of the above

24. Which of the following is a big reason for discontinuities in smooth material flow?
Select one:
a. Long setup times

b. Long travel distances between machines

c. Poor quality

d. All of the above

25. Which of the following is not a part of setup time?


Select one:
a. Time to schedule the forklift driver to retrieve the die from storage

b. The time to make adjustments

c. The run time of the machine

d. The time to remove the old die from the machine

26. Which of the following is not a part of standard work?


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Select one:
a. The takt time

b. The work sequence

c. The in-process inventory

d. None of the above

27. Which of the following is not a target of the 2nd S?


Select one:
a. The cleanliness of the workplace

b. The orderliness of the workplace

c. The placement of tools based on frequency of use

d. Visual management

28. Which of the following is not an example of unnecessary items to be discarded as part of
the 1st S?
Select one:
a. Obsolete inventory

b. Excess inventory

c. Extra long wires

d. None of the above

29. Which of the following is used when some batching is done, especially where one machine
has significantly greater capacity as compared to other equipment?
Select one:
a. Production Kanban

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b. Withdrawal Kanban

c. Signal Kanban

d. None of the above

30. Which of the following systems has the ability to self correct when there is a change in
requirements?
Select one:
a. Pull

b. Push

c. Neither of the above

31. Which of the following would not be an example of Visual Management?


Select one:
a. An arrow indicating where something is located

b. A label identifying the part stored in a location

c. A computer printout specifying the production schedule

d. None of the above

32. Which of the three types of layouts has the most flexibility?
Select one:
a. Product type layout

b. Process type layout

c. Group layout/machine cell

33. Which ones of the following is not a reason to implement standards?


Select one:

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a. They form a base point for measuring improvement

b. They can be used for training

c. They help surface problems

d. They can be used to control worker behavior

34. Who is credited with developing time study?


Select one:
a. Henry Ford

b. W.E. Deming

c. Taiichi Ohno

d. Frederick Taylor

35. Why did Henry Ford double the wages of his workers while halving the selling prices of his
automobiles?
Select one:
a. To dissuade the workers from joining competitors

b. To create a mass market for his automobiles

c. Because he was a philanthropist

d. None of the above

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