Questions and Answers.

Multiple choice questions with answers.

1. Which of the following is not a muda?

a. Defects

b. None of these

c. Overproduction

d. Idle time

2. Which 5S phase focuses on cleanliness and dirt removal?

a. Shitsuke

b. Seiri

c. Seiso

d. Seiton

3. Which of the following metric is used in kaizen implementation?

a. Turnaround time
b. Average count of defective part

c. Takt time
d. cycle time
4. What triggers production when using Kanban system?

a. Forecast
b. any of these
c. the production planner
d. removal of product by downstream customer
5. Just in Time (JIT) means:

a. A lot of stock is kept to meet unforeseen demand.

b. Suppliers do not supply in time

c. Workers arrive at work punctually

d. Supplies are coordinated to arrive as they are needed

6. In the context of Just in Time systems, which statement about ‘kanban’ is false?

a. Kanban is a ‘pull’ system

b. When no output has been requested, operatives are encouraged to do

physical exercises to keep fit

c. Workstations are not allowed to produce anything without a Kanban

d. Physical form of a kanban may be a container in which the requested parts are

delivered

7. One of the requirements for implementing Just In Time is:-

a. Close ties between suppliers and the factory.

b. No scheduling for the production process is needed.

c. Bottlenecks on the production line do not need to be cleared.

d. Additional warehouse space is needed.

8. Value stream mapping looks at

a. The people, material, and information flow in a value stream.

b. The material and information flows in a value stream.

c. The steps people take in designing and producing a product.

9. JIT does not believe in

a. Quality

b. Over production

c. Human relations

d. All of the above

10. Which of the following is not a phase in Lean Project Delivery System?

a. lean design

b. lean supply

c. last planner system

d. project definition
11. Value stream represents the action needed to create a product from it’s …………..…
as raw material until it reaches a customer in it’s …………………. form.
A- Utility, operational
B- Simple, available
C- Inception, completed
D- Availability, original

12. Value streams include

A- Value added
B- Non value added
C- Both A and B
D- None

13. Value Stream Mapping (VSM) shows ……………….. And ………………….. Flows
required to produce outputs.
A- Skill and material
B- Material and information
C- Information and skill
D- Material and cash

14. Last Planner System (LPS) is to match ……………… and ……………… resources to
accomplish assignments in response to downstream demand
A- Labor and material
B- Material and financial
C- Financial and labor
D- All above

15. Last Planner System (LPS) is to match labor and material resources to accomplish
assignments in response to ……………… demand
A- Increasing
B- Decreasing
C- Downstream
D- Upstream
16. Look Ahead Schedule (LAS) is derived from phase plane and is used to
………………
A. Quality control
B. Workflow control
C. Schedule control
D. Cost and quality

17. Look Ahead Schedule (LAS) for design work could be from
A- 3-12 weeks
B- 4-14 weeks
C- 5-16 weeks
D- 8-20 weeks

18. Look ahead schedule should meet the following criteria

A- Manageable size
B- Readily measurable
C- Free of constraints
D- All above

19 Just In Time (JIT) is a ……………… system that responds to ……………… customer

demand
A- Flow, future
B- Push, increasing
C- Sophisticated, high
D- Pull, actual

20. The application of Just In Time (JIT) has a risk of the

A- Precision in deviation
B- Bulk demand
C- Inventories critical level
D- Customer satisfaction
21 -Just-in-Time was successfully implemented by
(A) Toyota
(B) Honda

(C) Suzuki

(D) Volkswagen

22 -In Just-In-Time system

(A) There is no delay

(B) Conveyance times are balanced

(C) Both (A) and (B)

(D) There is unequal production at different places

23-Such setups which have single digit (in minutes) setup times are called
(A) Single setups
(B) One touch setups

(C) Minute setups

(D) None of the above

24-POK stands for

(A) Product ordering Kanban

(B) Process Ordering Kanban

(C) Production Ordering Kanban

(D) Plan Ordering Kanban

25-In Just-In-Time the vendor is to be viewed by the company as a

(A) Manager

(B) Worker

(C) Partner
(D) None of the above
26-Just-In-Time is
(A) Single unit production
(B) Big lot size production

(C) Both (A) and (B)

(D) None of the above

27-MRP is different from JIT in terms of

(A) Inventory

(B) Quality

(C) Human orientation

(D) All of the above

28-The following is (are) the prerequisite(s) for JIT.

(A) Multi skilled workers

(B) Vendor should produce defect free

(C) Worker should be empowered his own decision

(D) All of the above

29-Just-In-Time aimed at
(A) Zero inventories
(B) Reduced manpower

(C) Over production

(D) All of the above

30-Which of the following means ‘Ready-Set-Go’

(A) Yo-i-don
(B) Ikko Nagare

(C) Taiichi ohno

(D) None of the above

31-Just-In-Time (JIT) combines the benefits of
(A) Job order production and Line production
(B) Batch production and Line production

(C) Job order production and Batch production

(D) None of the above

32-JIT does not believe in

(A) Quality

(B) Over production

(C) Human relations

(D) All of the above

VALUE STREAM MAPPING

33-VSM is a lean tool and its main purpose is

[A] Reducing tool change and toll setting time

[B] understanding the process and improving it

[C] Implementing 5S to improve workplace

[D] Reduce rejection

34- While plotting VSM

[A] Start from Incoming material and follow Material flow

[B] Start by identifying wastes and then operations then operations creating wastes creating
wastes

[C] Start by plotting value adding activities

[D] Start from customer’s requirements

35-VSM is used to describe,

[A] Only material flow

[B] Only information flow

[C] Only value adding activities

[D] None of above

36- In 7 Wastes, ‘Overproduction’ means

[A] Producing more than required

[B] Producing earlier than required

[C] Both [A] and [B]

[D] Neither [A] nor [B

37-Value adding activity means

[A] Activity that adds value to the product in the eyes of customers

[B] Activity that adds value to the product in the eyes of manufacturer

[C] activity that requires valuable resources

[D] None of above

38-TAKT TIME helps us to calculate

[A] Time to be allocated for each operation

[B] Non value adding time

[C] Value adding time

[D] Overall Equipment Effectiveness (OEE)

39. Lean manufacturing is a(n)
a. Fad
b. Method for reducing labor
c. Way to improve customer value
d. Efficiency improvement technique

40. Customer value is defined as

a. Cost
b. Delivery
c. Reliability
d. Response
e. All of the above

41. The five “W’s” of Root Cause Analysis are

a. Who, what, where, when, why
b. What, where, when, who, why
c. Who, who, who, who, who
d. Why, why, why, why, why

42. Cycle time is

a. Elapsed time from customer order to payment
b. Reduced to eliminate jobs
c. The amount of time the machine runs
d. Improved by larger lot sizes
43. Cycle time efficiency is
a. Improved by increasing utilization
b. The machine cycle divided by number of pieces produced
c. Increased by larger lot size
d. Value added time over elapsed time
44. One-piece-flow means
a. Batch
b. larger lot sizes
c. One piece moves to the next operation
d. Operators need to work harder

45. Statistical process control charts include all the following except
a. Upper control limit
b. Sample average
c. Product specifications
d. Sample range

46. The primary focus of any improvement activity is the elimination of

a. Workers
b. Waste
c. Flexibility
d. Decision making at the lowest level
47. In a manufacturing cell, who has authority to stop production?
a. The line supervisor
b. Machine operators
c. The material handler
d. All of the above

48. In a cell, the operator is responsible for

a. Maximum production output
b. Meeting customer demand
c. Just the machines they are running
d. Directing request to the supervisor

49. Lean manufacturing uses which of the following techniques

a. Economic order quantity
b. Make to stock
c. Run whatever material is available
d. Excess capacity

50. The main purpose of set up reduction activity is to

a. Run smaller lot sizes
b. Make higher production
c. Eliminate set up personnel
d. Charge more per hour

51. Set up reduction involves all of the following except

a. Define internal and external tasks
b. Mistake proofing
c. Add adjustments to fixturing
d. Keep tools and gages in kits

52. Pilot projects should be chosen based on

a. Total savings to the company
b. Anticipated chance for success
c. The number of people affected by the changes
d. All of the above

53. The worst that can happen in a pilot project is

a. Total failure of the company
b. People’s jobs will be eliminated
c. Having to change it back
d. All of the above
54. The term value chain means we include the supply chain in our analysis and
management with
a. end consumer
b. the downstream portion of the chain and distribution, such as
marketing
c. channels of distribution
d. financial impact studies

55. Kanban system minimizes through backward requests.

a. Inventories
b. Cost
c. Time
d. Variation

56. Flow Kaizen methodology is concerned with _.

a. Elimination of waste
b. Elimination of cost variation
c. Continuous improvement
d. Value stream
57. Which of the following area of work is not best
suited for 5S METHODOLGY?
a. Reducing Human efforts
b. Inventory practices
c. Customer satisfaction
d. Layout Planning
58. Involves trying new construction ideas on a pilot
basis and applying the PDCA (Plan-Do-Check-Act) methodology.
a. Last Planner System
b. Value Stream Mapping
c. First-Run Studies
d. Kanban system

59. Clarifies the corrective action that are needed and is

linked to the look-ahead plan.
a. First-Run Studies
b. Constraint Analysis
c. Daily Work Plan
d. Reverse Phase Scheduling

60. Tool used in Root cause analysis

a. Bar charts
b. Pareto Charts
c. Scatter diagram
d. Fishbone diagram

61. Statistical technique used for determining the proportion of time spent
by workers in various defined categories of activity.
a. Value analysis
b. Work sampling
c. Reverse Phase Scheduling
d. Statistical control
 62. Phase that emphasis on work and its requirements, completeness are
clear_____________ .

a. Value Stream Mapping

b. Commitment Planning
c. Look-Ahead Planning
d. Reverse Phase Scheduling

63. A dealer will start the assembling and verification of the vehicle parts
only when there is an order, the concept adopted is _________.
A. Lean Manufacturing
B. Kaizen methodology
C. Last planner system

D. Just in time

63. The LEAD TIME is?

a. The value-added time
b. The crossing time of a process
c. Working time of employees
d. None of the above

64. Process Kaizen focuses on

a. Waste elimination
b. Continuous improvement
c. Value stream mapping improvement
d. financial impact studies
65. Order of Five S strategy used
a. Set in Order, Shine, Sort, Standardize, Sustain
b. Shine, Sort, Set in Order, Standardize, Sustain
c. Sort, Shine, Set in Order, Standardize, Sustain
d. Standardize, Sort, Shine, Set in Order, Sustain

66. Short meeting usually taking only about few minutes conducted by
the team leader before the start of the day or shift.
A. Daily huddle
B. Team huddle
C. First gathered meeting
D. Morning huddle

67. Fact finding tool used to measure activities and delays while
working.
a. Cause and Effect analysis
b. Work sampling
c. Activity definition model
d. Feasibility Analysis

68. What does kaizen mean, when translated from

Japanese into English?

A. Change for the better

B. Change slow

C. Process change

D. Process slow
69. PQI Stands for
a. Process Quantity Index
b. Project Quality Indicator
c. Process Quantity Indicator
d. Project Quality Index

70. Who should work on a root cause analysis?

a. Only area supervisor(s)

b. Only the supervisor and the Quality Manager

c. The people who are close to the work on a daily basis

d. Only the people who identified a non-conformity

71. POK stands for

a. Product ordering Kanban
b. Process Ordering Kanban
c. Production Ordering Kanban
d. Plan Ordering Kanban

72. What is root cause analysis?

a. A technique used to determine why a problem occurs in
the first place.
b. A tool used by arborists to get the best growth rate from trees.
c. A system to qualify LM suppliers in P2P.
d. A Six Sigma method of eliminating waste from a process
 73. JIT does not believe in
a. Quality
b. Over production
c. Human relations
d. All of the above

74. In JIT system

a. There is no delay
b. Conveyance times are balanced
c. Both (A) and (B)
d. There is unequal production at different places

75. VSM is also called?

a. CCV: Connection Critical Value
b. MIFA: Material and Information Flow Analysis
c. MFIM: Mapping Flow and Inventory Material
d. None of the above

76.
77.

78.
79.

80.
 81.

82.

83.
84.

85.
1. The first run studies involves the application of methodology
2. At Toyota, value stream mapping is referred to as “ ”.

3. is the concept of continual incremental improvement.

4. and is two primary approaches to Kaizen improvement

activities.
5. Flow Kaizen emphasizes while process Kaizen focuses on the ________

6. is a technique which helps in avoiding wastes such as inventory of raw

materials, work in process, or finished assemblies that are not yet needed.

7. Which of the following best characterizes JIT systems

a. Build inventory at modest rate.

b. Annual review of operation methods

c. Pull method of materials flow

d. Push method of materials flow

8. Which of the following is NOT characteristic of a kanban system?

a. It serves as a push mechanism.

b. At least one card is associated with a container of process

input material.

c. It controls the movement of containers from source/storage to

the production process.

d. Each container contains equal numbers of non-defective parts.

9. ____________ is the time taken to move one transaction through the
entire process—before another transaction can begin.

10. Which diagram is NOT a part of value stream mapping?

a. Current state drawing

b. Future state drawing

c. Transitional phase diagram
d. Implementation plan

ANSWERS

1. PDCA (Plan Do Check Act)

2. Material and Information Flow Mapping

3. Kaizen

4. Flow Kaizen and Process Kaizen

5. Value stream improvement, elimination of waste.

6. JIT

7. c. Pull method of materials flow

8. a. It serves as a push mechanism.

9. Lead time

10. c. Transitional phase diagram