Week 1

1. The central idea of Toyota Production System is to……

Improving product quality without increase in cost

Increasing the value adding activities for increasing the customer satisfaction
Both a and b
None of these

2. Toyota Production system is based on elimination of waste from the process. Here waste should
be defined from

Customer perspective
Manufacturer perspective
Both A and B
None of these

3. Which of these are correct about the global environment of manufacturing sector?

Boom in China contribution to global manufacturing

Opportunities for newer manufacturing destinations
Both a and b
None of these

4. Which of the following can be classified as non-value adding activities in Toyota Production
System?

Underutilization of people’s talent, skills and knowledge

Production of defective parts
Extra-processing for getting higher quality than required
All of these

5. The basis of manufacturing excellence in Toyota Production System is

Continuous efforts to reduce the cost

Eliminating waste from processes for delivering the customer satisfaction
Both a and b
None of these

6. Factors of operations management, which provides competitive advantages to a firm are

Cost and Quality

Better customer service
Employee happiness
Both a and b

7. Production system can be classified based on

Flexibility
Human involvement
System output
All of these

8. Which of the following is not an element of a production system?

Getting the customer voice

Input material
Value addition
Transformation to final output

9. Competitiveness can be influenced by

Marketing
Operation
Both of these
None of these

10. To accomplish organizational strategy of quality the corresponding operations strategy is based
on:

High performance design

Innovative product
On time delivery
All of these

Week 2

1. Foundation of Toyota production system (TPS) focuses on-

Long-term philosophy
Short-term philosophy
Both A and B
None
2. 4P’s of Toyota production system (TPS) are-

People, promotion, profit, partnership

Product, price, place, promotion
People, partner, price, process
Partner, problem, philosophy, process

3. Toyota production system (TPS) believes in-

Right process will lead to right results

Reducing the waste from the system
 Respect your extended networks of partners and suppliers
All of the above
4. JIT does not believes in-

Pull concept
Push concept
Inventory Management
All of the above
5. Which of the following means is used by Toyota production system (TPS) to minimize the over-
production?

Muda
Jidoka
Heijunka
All of these
6. Consider the following two statements
I - Add structure (mass) for reducing noise and vibration in a vehicle
II - Cut noise vibration and harshness at the source (i.e., engine)
Which of the above two statements is correct regarding the Lexus production?

Only I is correct
Only II is correct
Both I and II are correct
Both I and II are incorrect
7. Which of the following is correct ?

Goal of Lean Manufacturing is to apply the ideal of one piece flow to all business operations, from
product design to launch, order taking, and physical production.
Goal of Lean Manufacturing is to reduce inventory level.
Goal of Lean Manufacturing is to reduce safety stock level.
All of the above
8. The roof of TPS house projects-

The objective of the TPS

The processes used in TPS
The product deliver by TPS
Standardisation of process
9. Which theory is based on “No defect should leave the station”?

Lean
Heijunka
Kanban
Jidoka
 10. The important consideration for new product development is (are) –

Effectiveness of the product

Less Input
Price of the product
Efficient Production

Week 3

1. The primary goal of a pull system is to

Keep track of task time

Eliminate the overproduction
Eliminate the defects
All of these
2. The purpose of implementing pull system is to

Build products based on forecasted demand

Build products based on actual demand
Both of these
None of these
3. What is a Kanban?

A method of value stream mapping

A Method for operationalizing pull control
The Japanese word for waste
A Method to ensure capacity utilization

4. Which of the following is correct Japanese Terms Meaning

(i) Muda (p) Overburden
(ii) Muri (q) variation
(iii) Mura (r) Non Value Added

(i)- p, (ii)- q, (iii)- r

(i)- q, (ii)- p, (iii)- r
(i)- (r), (ii)- p, (iii)- q
(i)- q, (ii)- r, (iii)- p
5. Which of the following is not a benefit of heijunka?

Predictability
Flexibility
Stability
None of these
 6. What is Jidoka?

A process that eliminates wasted time, resources, effort, and money wherever it can
The idea that machines would be able to work just fine on their own until some error occurs, at
which time the machine signals for someone to come fix it
An idea that states when a problem occurs it should be fixed immediately, but once a solution is
found, a process should exist for making sure that the problem doesn't happen again
An idea that allows for more employee downtime in the hopes that they will become more creative
and come up with more ideas for company success
7. In TPS, the purpose of standardizing the task is

To increase the efficiency of the system

To increase the flexibility of the system
Both of these
None of these
8. Which of the following is/are the benefit of using visual control?

Safer workplace
Improved Productivity
Improved Output
All of these
9. In 5S the term sorting means

Only have the needed tools and resources in the area

Keep it clean
Make sure you follow up
Ensure everyone is doing it the same way

10. Which of the Toyota principle helps pull system to deliver evenness?

Kanban
Visual system
Level out of work
All of these
Week 4

1. Which of the following is/are correct regarding the use of new technology in Toyota Production
System.

New technology must add value to the process

Technology adopted must focus on waste elimination also
Both of these
None of these

2. Which of the following is not describing the reliable technology in TPS correctly.
 Technology must serve people both your people and processes.
Valuing people more than technology
Must adopt innovative technology that serve primarily your process
None of these
3. Which one of the following principle is given by Genchi Genbutsu

Go to gemba and see for yourself to thoroughly understand the situation

Make decision slowly by consensus (use cross functional teams)
Become a learning organization through relentless reflection (hansei) and continuous improvements
(Kaizen)
Respect your extended network of partners and suppliers by challenging them and helping them
improve.
4. Hourensou rapid genchi genbutsu is for firm executives which says-

To serve some of the genchi genbutsu functions, senior management uses hourensou,
To keep in touch with what is happening
Both a and b
None of these

5. Which of the following is correct from TPS point of view?

Organizations should generally hire Top leaders from outside.

Organizations should generally develop internal leadership.

Organizations should have mix of internally developed and externally hired top leadership.
Organizations should take decision of top position based on the business environment.
6. Which of the following is central aspect of TPS?

Technical
Management
People
Philosophy
7. Which one of the following is correct?

Top leaders are responsible for value addition.

Work teams are responsible for value addition.
Any individual in the organization is capable of value addition.
all of the above

8. Which one of the following is correct?

According to TPS, balance is needed between individual excellence and team effectiveness.
According to TPS, balance is needed between individual effectiveness and team excellence.
 According to TPS, balance is needed between individual and team excellence.
According to TPS, balance is needed between individual and team effectiveness.

9. Which of the following is correct?

According to TPS, we should make our partners comfortable.

According to TPS, we should challenge our partners.
According to TPS, partners make you uncomfortable.
All of the above
10. Which of the following is correct?

TPS suggests to switch supplier in search of cheaper supplier.

TPS suggests to have high expectations from the suppliers.
TPS suggest to have low expectations from the suppliers.
Only (a) and (c) are correct.
.

Week 5

1. Which one of the following Japanese terms is described as ‘consensus building’ in Toyota
Production System?

Gembutsu
Kaizen
Nemawashi
Hansei

2. Which of the following constitutes the principle 13 – “Thorough consideration in decision

making” of Toyota Production System

Considering alternative solutions and developing detailed rationale for the preferred solution.
Building consensus within the team, including Toyota employees and outside partners.
Using visual communication rather than descriptive one.
All of these
3. Which of the following best describes a learning organisation?

Organisation members take corrective actions

Organisation members see errors as opportunities
Organisation members are constantly learning from everything they do.
All of the above.
4. What is the first step in 5S implementation?

Waste identification
5S implementation team formation
Training and orientation of employees
5S manual and process details are developed

5. Which 5S phase finds storage space for every needed tool or instrument and the spaces are
properly marked

Seiso
Seiton
Seiketsu
Seiri
6. Which one of the following techniques is not used for making the process lean?

Single Minute Exchange of Die

Reverse Engineering
Kanban
Rapid Prototyping
7. Which of the following is correct?

For becoming a learning organization, all employees must undergo regular training.
Continuously solving root problem drives organizational learning.
Organizations become learning organizations by getting employees from top ranking universities.
None of the above
8. Which of the following is correct with reference to modern business environment?

It is characterized by homogeneous markets.

It is characterized by shorter product life cycles.
It is dominated by quality and cost issues.
All of the above are correct.

9. Which of the following is correct?

TPS is generally limited to manufacturing department.

TPS cannot be implemented in services organizations.
TPS implementation makes people use lean concepts in personal life also.
None of the above
10. Which of the following is correct?

Application of lean should start from unique processes.

Application of lean should start from repetitive processes.
Application of lean should start from first process.
Application of lean should start from longest process.
 week 6

1. Agile manufacturing primarily delivers cost and ……….. to an operation?

Flexibility
Cost
Quality
None of these
2. Lean production primarily delivers cost and ……………. to an operation?

Flexibility
Quality
Both a and b
None of these
3. Which of the following is used for ensuring customer voice into the product design?

Concurrent engineering
Quality function deployment.
Both a and b
None of these
4. Which of the following are the focuses of the sustainable manufacturing system?

Lean production
Focusing on customer requirement.
Environment
All of these

5. The purpose of employing sustainable manufacturing system is to have….

More competiveness
Reducing hazardous waste
Both a and b
None of these

6. Which of the following is not a preferred waste management in sustainable manufacturing?

Open dumping
Waste to energy transformation
Recycling
None of these
7. Which of the following is not the type of FMS?

Flexible manufacturing cells

Flexible machining system
 Flexible tool handling system
Flexible transfer line
8. Which of the following is not the benefit of Flexible manufacturing systems (FMS)?

Inventory reduction
Less requirement of skilled labour
Increased utilization
Lead time and throughput time requirement
9. Which of the following is not a market requirement in terms of flexibility?

Product variety
Product customization
Product innovation
None of these
10. Which of the following is not correct with reference to Benchmarking?

It is done to reduce cost.

It is done to know “what is possible”.
It is done to hire the best employees.
It is done to gain competitive edge.

Week 7

1. Which of the following is not a part of lean culture?

Continuous improvement
Remove waste
Faster innovation in products
None of these
2. Which of the following statement given below is/are correct?
I. Lean culture focuses on the value addition for their customer
II. Lean culture is implemented for providing higher service level to their customers

Only statement I is correct

Only statement II is correct
Both statements I and II are correct
Both statements I and II are incorrect

3. Which of the following is/are the workplace efficiency tool designed to combine product flow and
information flow along with any other useful data?

Benchmarking
Value stream mapping
Both of these
None of these

4. Which of the following statements regarding lead time is TRUE?

Lead time is more in push system

Lead time is more in pull system
Both of these
None of these

5. Which of the following is/are the part of lead time reduction process in TPS?

Reducing the no of value adding activities

Eliminating non-value adding activities
Combining two or more value adding activities into one activity
All of these
6. Which of the following is not a performance outcome of lean operating system?

Quality
Cost
Information
Delivery

7. Which of the following is not a lean implementation strategy?

Value stream mapping

Targetting specific measurable business objective
Cash the check
Enterprise resource planning

8. Which of the following is correct?

In total lead time, nonvalue added time is generally more than value added time.
In total lead time, value added time is generally more than nonvalue added time.
In total lead time, value added and nonvalue added times are generally same.
The ratio of value added and nonvalue added times cannot be specified in the total lead time.
9. Value stream mapping shows flow of ……….

only material
only information
material and information
material, information and funds
10. What is cycle time?

Rate at which a part is demanded

Rate at which a part or product is completed by a process
Time to complete all the processes to make a part or product
Time to consume a batch of par or product

Week 8

1. Calculate the number of Kanbans if the hourly demand is 100 units, lead time is 10 hours,
container capacity is 120 units, and variation in lead time is 15%.

10
12
15
18

2. ……………. Signals the need to produce more parts and …………. signals the need to deliver more
parts to the next work center.

P – Kanban, C- Kanban
P – Kanban, P - Kanban
C – Kanban, C- Kanban
C – Kanban, P- Kanban
3. Which of the following is not the characteristics of Kanban?

Minimize cycle time

Continuous delivery
Limit the work in progress (WIP)
None of these

4. Which of the following is /are correct regarding the Kanban system?

Kanban includes visualizing the workflow

Work in progress is limited in each workflow state
Both of these
None of these

5. Which of the following is correct about a Kanban card?

Kanban card is a way of signaling which part is available

Kanban card is attached to each item to provide details of the transaction history
Kanban card is destroyed once a bin is empty
Kanban card is a message that signals the actual status of the item or parts.
6. When is a signal to replenish stock sent in a Kanban’s two bin system?
When an item is taken from the first bin
When both the first and second bin is empty
When the first bin is empty
When the first bin is half way done
7. Which one of the following awards is given for excelling in the quality control and businesses that
have successfully implemented Total Quality Management (TQM)?

Malcolm Baldrige National Quality Award

Deming Prize
Golden Peakock Nationality Awards
European Foundation for Quality Management
8. Which of the following is not a criterion included in awarding the Malcolm Baldrige National
Quality Award?

Leadership
Benchmarking
Strategic Planning
Customer and Market Focus

9. Which of the following is correct in context of Theory of Constraints?

There are many systems where there is no constraint.

There are few systems where there is no constraint.
Each system has at least one constraint.
Each system has many constraints.

10. Which of the following is not a core element of Theory of Constraints?

(i) Focus
(ii) Follow Through
(iii) Excellence

(i)
(ii) and (iii)
(iii)
(i) and (ii)