42 Answered Test Questions:
1. The various kinds of Kanban include:
Answers:
• Supplier Kanban
• In-Factory Kanban
• Customer Kanban
• In-House Kanban
• All of the above
2. What are the three C's essential for Supply Chain Management?
Answers:
• Cooperation
• Communication
• Coordination
• Customer Satisfaction
3. Why did Ford begin to lose its hold in the market?
Answers:
• There were clashes between the laborers and the Ford system
• There was a sudden rise in the product variety
• Annual changes in models and multiple colors and options suited the Ford factories
• All of the above
4. Which of the following is necessary for the success of Lean implementation?
Answers:
• There needs to be a total cultural change in the organization
• The command-and-control approach needs to be imbibed
• The people have to be downsized
• The value stream has to be mapped
• The senior mangement need not be active participants in the Lean implementation program
5. Which of the following are true regarding value stream mapping?
Answers:
• It is a tool to look at how value flows into and through a process to the customer
• It cannot be applied to service processes because the value stream cannot be traced in these processes
• It helps to locate the wastes in the value chain
• It cannot be used to map information flows
6. Which principle of Lean makes use of spaghetti charts?
Answers:
• Value
• Flow
• Value Stream
• Pull
7. Where was the first TPM conference held?
Answers:
• Canada
• Japan
• The United Kingdom
• The United States
8. Pull System is another name for ______.
Answers:
• Poka-Yoke
• Kanban
• Standard Work
• SMED
9. Which method helps in the optimization of machinery?
Answers:
• FMEA
• Total Productive Maintenance
• Kanban
• Cycle Time Reduction
10. Cycle Time Reduction is:
Answers:
• the time needed to complete a task within a process
• the time needed to manufacture a product
• the time needed to design a product
• the time needed to deliver a product to the customer
11. State whether true or false:
Applying Lean to Supply Chain Management helps to certify the suppliers.
Answers:
• True
• False
12. Which of these need not be a feature of Lean metrics?
Answers:
• They are fundamental for decision-making purposes
• Building a Lean enterprise is an important basis for good metrics
• They should be made keeping in mind the goals of the competitor
• They should be simple to understand and presented in a clear manner
13. Which of the following losses does not eliminate TPM?
Answers:
• Breakdown losses
• Production losses
• Speed losses
• Quality losses
14. What is the main reason for the occurrence of waste?
Answers:
• Single Unit Processing
• Inventory
• Cycle Time
• Lean Manufacturing
15. Which of the following is not done by poka-yoke?
Answers:
• It easily recognizes flaws in a product and thwarts the manufacturing of incorrect parts
• It signals and specifies a trait in a product or a process
• It helps in the optimization of resources in an organization
• It is the first step in proofing a system
16. What is the function of SMED?
Answers:
• To increase output and quality losses
• To reduce the changeover in a process
• To improve supplier relations
• All of the above
17. Who is known as the "father of scientific management"?
Answers:
• Henry Ford
• Shigeo Shingo
• Frank Gilbreth
• Frederick Winslow Taylor
18. Whom did the four locations on the large board of the Beer Game not represent?
Answers:
• The Factory
• The Distributor
• The Customer
• The Wholesaler
19. Which of the following is not a Lean Tool?
Answers:
• Standardization
• 5s-Cando
• Kanban
• Design of Experiments
20. Which of the following cannot be considered a waste?
Answers:
• Waiting time
• Overproduction
• Skilled plant workers
• Long process setup
21. What is the formula to calculate cycle time?
Answers:
• [Inventory (units)] / [Demand (units/time)]
• Available work time / Customer required volume
• Customer required volume / Available work time
• None of the above
22. What does Kanban mean?
Answers:
• A card-signal
• A go ahead signal
• A warning-signal
• None of the above
23. For any company to reach a 'level 6' sigma, there should only be _______ defects per million opportunities.
Answers:
• 1
• 2.2
• zero
• 3.4
24. What is the similarity between Lean and Six Sigma?
Answers:
• Both view waste as anything that does not produce value
• Both focus on process flow
• Both deliver higher quality of service with greater speed
• None of the above
25. Synchronous Flow Manufacturing plans inventory around:
Answers:
• Capacity Enhancing Resources
• Capacity Defining Resources
• Capacity Constraint Resources
• capacity Cutting resources
26. The data that does not need to be communicated in a Visual Factory environment are:
Answers:
• process metrics
• the name of the employees
• work instructions
• general plant information
27. What is also known as 'law zero' in Lean Six Sigma?
Answers:
• The Law of Waste
• The Law of the Market
• The Law of Focus
• The Law of Competition
28. Which of the following is not synonymous with Lean Manufacturing?
Answers:
• World Class Manufacturing
• Wasteless Manufacturing
• Continuous Flow Manufacturing
• Stockless Production
29. Who introduced the concept of mass production?
Answers:
• Frank Gilbreth
• Henry Ford
• Benjamin Franklin
• Frederick Winslow Taylor
30. What is Takt Time?
Answers:
• The time required to manufacture a product
• The consideration of customer demands and the time of the demands
• The time between the order and the delivery of the product
• None of the above
31. Which of the following is true with regard to Synchronized Flow Manufacturing?
Answers:
• It means coordination between plant workers and management
• It means processes and related decisions in the management must be synchronous with each other
• It improves the manufacturing system by setting off an increase in operating costs
• It means that all parts of the system must be continuous and in harmony with each other to avoid inventory pileups and stoppages.
32. A flexible process is:
Answers:
• an expensive and time consuming process because it requires change of equipment and tools for different customer demands
• one which can be reconfigured to give different output for different customer demands
• a 'push' system
• one that generates a level and consistent schedule
33. Which of these features does not describe the features of the Ford system?
Answers:
• Materials do not go from "dock to stock" but from dock to the factory floor
• Inventory binds capital and getting rid of inventory frees capital
• Pull system
• Reducing the cycle time also frees capital
34. Who among the following is involved in the implementation of Kaizen?
Answers:
• Top Management
• Suppliers
• Workers
• Customers
35. How many wastes are identified by Lean?
Answers:
• Only 1
• 10
• 8
• 100
36. What is not an advantage of SMED?
Answers:
• It helps to achieve consistency in the process
• It helps in continuous improvement of the process
• It increases elasticity in the process
• It is a measure of performance
37. Six Sigma processes are implemented by organizations to reduce __________.
Answers:
• defects in their processes
• costs of poor quality
• infrastructure defects
• process improvements
• employees
38. What is the main function of Lean?
Answers:
• Eliminating muda
• Increasing cycle time
• Downsizing personnel
• Improving process capability
39. According to the Theory of Constraints, ______________________.
Answers:
• every process or system has a constraint that acts as an impediment in attaining less of its goal
• the manufacturing process is enhanced by its capacity constraint resource
• every process or system has a constraint that acts as an impediment in attaining more of its goal
• time lost at a constraint can be gained back
40. _________ means to clear the work area.
Answers:
• Sort
• Set in Order
• Shine
• Standardize
41. What are the advantages of applying Lean to a supply chain?
Answers:
• It helps speed up the expansion and execution operations
• It turns the organization into a major customer of all the suppliers they have dealt with
• It helps to decrease the number of variables with which the production, quality and dependability has to cope with
• All of the above
• None of the above
42. State whether true or false:
Single unit manufacturing cannot be approximated to continuous flow manufacturing.
Answers:
• True
• False
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