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Lean Practitioner Quiz – Dawn Hudgins 12/21/15

1. Lean operations tend to achieve all of the following except

a) Greater productivity
b) Shorter cycle times
c) Increased Inventory
d) Lower costs

2. Many lean operation methods used today were derived from which Japanese car makers approach to
a) Hyundai
b) Ford
c) Toyota
d) Honda

3. Replacing material or parts based on customer demand is an example of

a) Heijunka
b) Kaizen
c) Pull System
d) Kanban

4. Workers who perform several parts of a process and operate a variety of machines are
e) Cross-trained
f) Team-based
g) Problem-solvers
h) Cooperating

5. Which of the following systems is used to reduce changeover time

a) SMED (single minute exchange of die)
b) TAKT time
c) Kanban
d) Push system

6. TAKT time is computed using the equation (net time available per day divided by)
a) Work in Process
b) Daily Demand
c) Break Time
d) Number of Shifts

7. The ultimate goal of lean operations is

a) Activity-based costing
b) Balanced and flexible system
c) Kaizen philosophy
d) Modular design
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
8. In the context of Just In Time systems, which statement about ‘Kanban’ is false
a) Workstations are not allowed to produce anything without a Kanban
b) Physical form of a Kanban may be a container in which the requested parts are delivered
c) Kanban is a ‘pull’ system
d) When no output has been requested, operatives are encouraged to do physical exercises to keep fit

9. Which of the following is NOT a part of the seven types of waste

a) Inventory
b) Processing
c) Transportation
d) Preventive Maintenance

10. Which Toyota approach is about safeguard built into a process to reduce the possibility of error
a) Heijunka
b) Poka-yoke
c) Jidoka
d) Kaizen

11. A Kanban system is used to manage

a) Operational Efficiency
b) Prevention of Defects
c) Automation
d) Inventory

12. Which of the five S's is used to decide which items are needed to accomplish work
a) Standardize
b) Self-discipline
c) Sort
d) Straighten

13. What is TRUE about Value Stream Mapping

a) Captures activity network diagram
b) Captures material and information flow
c) Captures only value added steps
d) Captured only non-value added steps

14. A lean organization strives to create

a) Improved Employee Morale
b) Specialists in each department
c) A population of problem solvers
d) Annual Kaizen events

15. I. Value stream mapping examines the flows of materials and information.
II. Unfortunately, it doesn't help identify waste and opportunities for improvement.
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
a) I is True and II is True
b) I is True and II is False
c) I is False and II is True
d) I is False and II is False

16. What is preventive maintenance:

a) Housekeeping
b) Fixing the manufacturing process
c) Keeping the equipment in good operating condition
d) Raising the breakdown issue before it happens

17. What is a benefit of the 6S's:

a) Increased productivity
b) Improved employee morale
c) Reduced risk of accidents
d) ALL of the above

18. What is not TRUE about Kanban

a) In an MRP, the Kanban can be thought of as a "build" authorization
b) Each pull station can require only one resupply component
c) If the producer & user are not in visual contact, a light spot on the floor to be used as a signal
d) The Kanban cards provide a direct control on the amount of work-in-process between cells

19. In lean systems, if a defective product if found, which of the following is generally NOT done?
a) The production line is stopped
b) The defective unit is passed on to the next workstation
c) The defective unit is returned to the worker responsible for creating the defect
d) The production line is made aware of the problem without stopping the line

20. Which of the following illustrates an activity that does not add value?
a) Training employees
b) Ordering parts from a supplier
c) Accumulating parts in front of the next work center
d) Delivering the product to the customer

21. Employee empowered companies have committed to all but one of the following
a) Investment in people
b) Use of information technology to support decision making
c) Link compensation to short term performance
d) Develop training programs for employees

22. Overall Equipment Effectiveness (OEE) is

a) Quality Rate X Availability Rate X Performance Rate
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
b) Mean Time Between Failures (MTBF)
c) Mean Time to Repair (MTTR)
d) Maintainability X Performance X Speed

23. Which is the following approaches is a basic component of Lean

a) Requiring suppliers to maintain surplus inventory of raw materials
e) Giving team of workers more responsibility of the production process
f) Establishing rewards based on production metrics
g) Using specialized resources and tools to create products

24. A pull system is best defined as a system that

a) Tracks a variety of inventories
b) Stores customized inventory
c) Produces inventory when the customer signals a need
d) Produces inventory in concert with an established production schedule

25. Which is not a benefit of small lot sizes

a) Reduced Inventory
b) Increased Production Flexibility
c) More Frequent Set-ups
d) Less re-work if problem occurs

26. Kano Model is used to

a) Understand customer expectations
b) Categorize and prioritize customer expectations
c) Predict failure rates
d) Create sales patterns

27. Which of the following sources provide the clearest voice of customer?
a) Customer Complaints
b) Customer Focus Groups
c) Sales Representative Interviews
d) Sales Trend

28. The TAKT Time is inversely proportional to

a) Cycle Time
b) Demand
c) Available Time
d) Wait Time

29. An automated process is assumed to be running in two shifts of 8 hrs each with operator’s scheduled
breaks for 1 hr. per shift. The demand per day is 1440 pieces. Calculate the TAKT Time.
TAKT Time = 40
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
30. The tool to convert VOC (Voice of Customer) in Technical Specification is
a) Standard Work
b) Kanban
c) QFD
d) Defect Metrics

31. A process has total inventory (RM+WIP+FG) of 2000 pcs with average demand per day as 200 pcs. The
total cycle time for the process is 240 seconds. Calculate Process Cycle Efficiency.
PCE = 0.028%

32. Calculate Re-order point (ROP) for the following, Annual Demand = 3600, Lead Time = 15 Days
(Assume 300 working days per annum)
a) 225
b) 375
c) 180
d) 1800

33. Safety stock does not accommodate

a) Variation in Lead Time
b) Productivity Losses
c) Variation in Demand
d) Customer Service Level

34. Calculate Total Inventory Cost and EOQ for the following: Demand per annum = 36000 Unit, Cost per
Unit is $20, Holding cost is 30% of the item cost, The ordering cost per order is $240 and Order Size is
Total Annual Inventory Cost = $3,660
EOQ = 537

35. A company should do which of the following to reduce work-in-process (WIP)

a) Install control that enable workers to make process adjustments as needed
b) Increase lot sizes to reduce the number of runs needed
c) Establish in-line inspection
d) Implement Single Minute Exchange of Dies (SMED)

36. A Kanban card is used to signal that

a) A machine has broken down
b) A worker is falling behind and needs help
c) A defect has occurred
d) Parts are needed

State if following statements are True / False

37. Pull System recommends to schedule bottleneck only and other processes to work in-tandem with the
bottleneck (True / False)
38. The purpose of SMED is to achieve small lot production (True / False)
39. 5S is a good tool to identify waste of motion (True / False)
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
40. One piece flow helps reducing WIP inventory (True / False)

41. A company should do which of the following to reduce work-in-process (WIP)

a) Install control that enable workers to make process adjustments as needed
b) Increase lot sizes to reduce the number of runs needed
c) Establish in-line inspection
d) Implement Single Minute Exchange of Dies (SMED)

42. Which of the following techniques uses outlines of tools or other items to indicate where they belong
on storage boards
a) Kanban
b) Standard Work
c) Andon
d) 5S

43. Place the 5s’s in the proper order:

a) Sort, Set-in-order, Shine, Sustain, Standardize
b) Shine, Sort, Standardize, Set-in-order, Sustain
c) Sort, Set-in-order, Shine, Standardize, Sustain
d) Sustain, Set-in-order, Shine, Sort, Standardize

44. One-piece-flow means

a) Moving 1 batch at a time
b) Moving 1 unit at a time
c) Moving 1 operator at a time
d) Moving 1 equipment at a time

45. What is not TRUE about SMED

a) It is organized based on External and Internal activities mapping
b) Machine with higher utilization to be focused first
c) All changeovers to be completed in 1 minutes only
d) Balancing of operator’s work load during changeover is important

46. Queue means

a) A signal to start production
b) A unit of measure (UOM)
c) Material should be pushed to the next operation when a batch is complete
d) Waiting
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
47. The correct sequence of VSM creation is
a) Identify Product Family  Draw CVSM  Calculate PCE  Calculate TAKT  Draw FVSM
b) Identify Product Family  Calculate PCE  Draw CVSM  Calculate TAKT  Draw FVSM
c) Calculate TAKT  Identify Product Family  Calculate PCE  Draw CVSM  Draw FVSM
d) Calculate PCE  Calculate TAKT  Identify Product Family  Draw FVSM  Draw CVSM

48. Which terms best relates to fail-proofing mechanism

a) Kaizen
b) Jidoka
c) Kanban
d) Poka-yoke

49. Suppliers for JIT systems are

a) Often located locally
b) Part of a company’s global outreach
c) Numerous, for each part
d) Always the one that offers the lowest price

50. Which of the following is an advantage of the ‘traditional’ approach to operations

a) Lower Inventory
b) Surplus Production
c) High capacity utilization
d) Fewer Stoppages

51. Customer is an entity who is willing to pay for the …………………of the product
a) Muri, Muda and Mura
b) Form, Function and Fitness
c) 7 Wastes associated with the processes
d) Administration and Quality activities

52. Which of the following is NOT an area of waste identified by Toyota?

a) Over-staffing
b) Motion
c) Over-production
d) Waiting

53. The concept of mass production was introduced by

a) Jack Welch
b) Mikel Harry
c) W. E. Deming
d) Henry Ford
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
54. …………..analysis relates to what processes, activities, and decisions actually create costs in your
supply chain
a) Cost driver
b) Customer Value proposition
c) Cost reduction
d) Target costing

55. A supply chain is made up of a series of processes that involve an input, a ……... and an output. 
a) Shipment 
b) Supplier 
c) Customer 
d) Transformation 

State if following statements are True / False

56. Supply Chain responsiveness focuses towards meeting a very high customer service level
(True / False)
57. Supply Chain Efficiency has nothing to do with cost of making and delivering a product to the
customer (True / False)
58. Efficient vs Responsive Supply Chain are synonymous (True / False)
59. Make/buy decisions are part of planning aspect of Supply Chain (True / False)
60. Demand Lead time is Zero for Make to Stock (MTS) scenario (True / False)

61. Inventory carried for the purpose of providing flexibility to each decision-making unit to manage its
operations independently is known as 
a) Decoupling inventory
b) Safety Stock 
c) Pipeline Inventory
d) Cycle Inventory

62. Cycle inventory helps in

a) Providing flexibility to each decision-making unit to manage its operations independently
b) Taking care of any special event that does not occur on a regular basis 
c) Finding out the amount of stock required during a finite period in order to move the materials
from one location to another 
d) Taking care of uncertainty in demand and supply of products / components

63. Safety stock calculation would include all except

a) Demand Variation
b) Lead Time Variation
c) Preventive Maintenance Time
d) Customer Service Level
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
64. SaveMart needs 1000 coffee makers per year. The cost of each coffee maker is $78. Ordering cost is
$100 per order. Carrying cost is 40% of per unit cost. Lead time is 5 days. SaveMart is open 365
days/yr. Calculate Economic Order Quantity (EoQ)
a) 80
b) 100
c) 120
d) 72

65. Calculate cycle stock for an Avg Monthly Demand of 1020 (30 days), Lead Time = 7 days
a) 7140
b) 238
c) 106
d) 216

66. Calculate Average Inventory value for an Opening Stock value of $70,000 and Closing Stock of $50,000
a) $70,000
b) $60,000
c) $50,000
d) $120,000

67. Which of the following relationships hold TRUE for the safety stock?
a) The greater the risk of running out of stock, the smaller the safety of stock
b) The larger the opportunity cost of the funds invested in inventory, the larger the safety stock 
c) The greater the uncertainty associated with forecasted demand, the smaller the safety stock
d) The higher the profit margin per unit, the higher the safety stock necessary

68. EOQ (Economic Order Quantity) helps minimizing

a) Inventory carrying cost
b) Ordering Cost
c) Total Inventory Cost 
d) Cost associated with the Safety stock

Match the following

69. Make to Stock=Focused Based Scenario
70. Quick Service Restaurants=Assemble to order
71. Customer Service Level=Average Daily Demand
72. Cycle Stock=Safety Stock
73. TAKT Time=Speed rate
74. Process Cycle Efficiency=Lead Time
75. OEE=NVA Time
76. Variety to the Customer Concept=General Motors
77. Specialization of the work=Ford Motors
78. Flexibility=SMED
79. Standardization=5S
80. Stability=Control charts
81. Reliability=Total Productive Maintenance
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
82. Which of the following is not a source of demand
a) Consumers – the end user of a product
b) Dealers and Distributors – channel of distribution
c) Service Needs – requirement from after sales service department
d) Component Requirements – planned by MRP

83. Product A is made from components B and C. Component B is made from parts D and E. Which items
should be forecast
a) Only A
b) A, B, and C
c) D and E
d) B, C, D, and E

84. Which of the following are primary activities of manufacturing planning and control
a) Inventory Management and Cost Information
b) Sales Support and Cost Information
c) Production Planning and Inventory Management
d) Sales Support, Implementation and Control

85. Which of the following parameters is considered while finalizing the product family for VSM
a) Sequence
b) Equipment
c) Time
d) Customer Type

86. If average demand for a given product is 24 pieces per day and 264 pieces of inventory is lying in WIP,
48 pieces in RM inventory and 72 pieces in FG. How many days of total inventory are carried.
a) 10 Days
b) 2 Days
c) 19 Days
d) 17 Days

87. Which of the following is not among 5 basic principles of lean

a) Value
b) Flow
c) Perfection

88. Assignable (Special) causes

a) are not as important as natural causes
b) are within the limits of a control chart
c) depend on the inspector assigned to the job
d) are causes of variation that can be identified and removed
Lean Practitioner Quiz – Dawn Hudgins 12/21/15
89. The philosophy of Zero defects is
a) The result of Deming’s search
b) Unrealistic
c) An ultimate goal; in practice; 1-2% defect is acceptable
d) Consistent with the commitment to continuous improvement

90. Change Management Practices should support which of the following types of Improvements
a) Operational Only
b) Financial Only
c) Both Operational & Financial
d) A Realignment of Authority

91. Which of the following is most likely to be a source of common cause of the variation
a) New employees in the department
b) A revised requisition form
c) A computer upgrade
d) The ambient temperature in the facility

92. Scheduling the bottleneck alone is an indication of Pull in the system (True / False)
93. One Piece Flow will help minimizing WIP in the progress (True / False)
94. Supermarket is created where it is difficult to create a perfect pull (True / False)
95. Control chart application will indicate the capability of the process (True / False)

96. Which of the following is not among 5 phases of perfection

a) Flexibility
b) Supervision
c) Standardization
d) Stability

Identify the waste/s in the following processes

97. A patient’s diagnostics report is replaced with other patient report
Defect Waste

98. Hollywood movie which virtually no one sees

Overproduction Waste

99. Cutting the crusts off your kids sandwiches when they are fine eating the crusts
Inventory Waste

100. Cabinets full of office supplies

Inventory Waste