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Lean Quiz

True/False
Indicate whether the statement is true or false.
 

 1. 

If there is no inventory before a processing cell that may mean a bottleneck.
 

 2. 

An IDEAL system is defined as infinite production, service quality and customer satisfaction with zero cost.
 

 3. 

Pull production may couse very high level of inventories.
 

 4. 

Work flow design usually are done around monuments.
 

 5. 

In lean manufacturing environment, one piece flow in each tact time is nor preferred because this may cause stop of production frequently.
 

 6. 

Shitsuke or sustain means “keep it working” and “keep people motivated”.
 

 7. 

Value stream maps can be used a great tool to eliminate waste within production.
 

 8. 

Value stream maps should be prepared for each cell first then they should be assembled to create the whole value stream map.
 

 9. 

DFQ (Design For Quality) is important because any rejected product from customer means a waste.
 

 10. 

Keeping equipment clean is one of the TPM jobs.
 

 11. 

You should describe the target condition of a project in quadrant 4 of A3.
 

 12. 

Project planning should be completed in quadrant 4 of A3.
 

 13. 

The question for quadrant 1 of A3 is “What are you talking about?”.
 

 14. 

The meaning of “Go to Gemba” is go and talk with the Lean leader.
 

 15. 

Lean Information Systems should have clear database documentation and DB connectivity tools.
 

 16. 

DFA means thinking production and assembly togather.
 

 17. 

If you apply DFM (Design for Maintainability) the product should only be repaired by customers.
 

Multiple Choice
Identify the choice that best completes the statement or answers the question.
 

 18. 

When sorting “What is needed” and “what is not needed” in the work place which of the following is not the aim.
a.
To reduce clutter in the area.
b.
To provide space to organize the work area effectively.
c.
To provide space for more in process inventory.
d.
To improve easy work access.
e.
To improve safety
 

 19. 

Which of the following do not belong to 5S.
a.
Sort
d.
Clean out the work place
b.
Stabilize
e.
Sustain
c.
Single minute exchange of dyes
 

 20. 

Which of the following are a kind of visual control?
a.
Kanban signal to pull mure material.
b.
An andon showing cell status.
c.
A graphical chart sticked on board to show defective parts per day     
d.
All of the above     
e.
Two of the above
 

 21. 

Which of the following can not take place in TPM training.
a.
How to oil, grease and perform other routine PM tasks
b.
Where the supplies about maintenance are located.
c.
How to determine the change times of replacable pieces.
d.
How to use an A3 form.
e.
All of the above can take place in TPM training.
 

 22. 

A3 form can be used for
a.
Teaching total prohibitive maintenance activities.
b.
Testing your employee about their expertise on their job.
c.
To collect and communicate on bright ideas about improving the work area.
d.
To give training around copy exactly idea.
e.
To advertise yourself to managers.
 

 23. 

For creating continuous improvement (keizen) besides the Lean Leader and cell leaders you should develop soppurtive leaders for which of the following areas?
a.
5S, VSM, SMED and TPM.
b.
Accounting, sales, purhasing and manufacturing.
c.
Kanban lines, supermarket inventories, floor and rack inventories.
d.
Project scheduling and depretiation calculations
e.
None of the above
 

 24. 

A3 is applied in the following conditions except
a.
Collaboration in thinking is required
b.
You need your thinking more visible
c.
You need your cell colligates thinking more visible
d.
You have a knowladge gap
e.
You think you know the solution and just need to test it
 

 25. 

In quadrant 2 of A3 the following questions should be answered exept
a.
What do I need to learn about this idea?
b.
Is it reasonable to work on this idea?
c.
What should I measure in the work area(Gemba)?
d.
All of the above
e.
None of the above
 

 26. 

For continuous improvement you can collect new ideas by the following except
a.
You can steal from other companies but respect the copyrights.
b.
You can give project awards in universities.
c.
You may use common consultants with your competitors.
d.
You may learn ideas from media.
e.
You can learn by kanban method.
 

 27. 

Which of the following is not a tool for JIDOKA (Elimination of Errors)
a.
Work instructions
d.
Visual Work Place
b.
Quality Function Deployment Matrix
e.
Monument Analysis Chart
c.
Failure Mode Effect Analysis Table
 

 28. 

Which of the following is the reason for SMED
a.
Consumers demand different products in low volumes and we should not push products to inventory.
b.
We don’t need too many dies in Lean Production.
c.
Multi minute exchange of dies may cause to fill up Kanbans.
d.
Lean manufacturing line should produce only one product for each day.
e.
All of the above
 

 29. 

In the case of “Tact Time = Cycle time” which tye of waste can be the outcome?
a.
Muda
d.
Motion
b.
Mura
e.
Transportation
c.
Muri
 

 30. 

Which of the following is not a Muda type of waste?
a.
Inventory
d.
Motion
b.
Waiting
e.
Transportation
c.
Unevenness
 

 31. 

Which of the following is not a Visual Management tool?
a.
Andon
d.
Pictographs
b.
Display boards
e.
Tact Time
c.
Cross training charts
 

Multiple Response
Identify one or more choices that best complete the statement or answer the question.
 

 32. 

SMED (Single Minute Exchange Of Dyes) is important because;
(One false answer will remove all correct selections)
 a.
It should be possible to switch between different products in very short time.
 b.
Otherwise push production cannot be possible.
 c.
Otherwise pull production cannot be possible.
 d.
Othervise in process inventory level decreases.
 e.
It should be possible to move monuments very quickly.
 

 33. 

Root couse analysis can be used for which of the following? (One false answer will remove all correct selections)
 a.
To find out reason for a dirty location in the work place.
 b.
To find out the reason of increased defective parts.
 c.
To find out standard time for a spesific job.
 d.
To calculate required space for a production cell.
 e.
To draw value stream map.
 

 34. 

Which of the sentences are belong to Lean thinking?
 a.
Developed by Taylor and Gilbreth and applied in Ford.
 b.
There is a single and best way of doing a job and engineers will find it.
 c.
Workers are not involved in design and improvement.
 d.
Workers should design the work.
 e.
Standardized work is a basis for future improvements.
 

Essay
 

 35. 

How can you save cost by applying Lean purchasing in your company?
 

 36. 

List at least 4 of the wastes that can be found by means of Value Stream Mapping. Explain for each how can it be detected within VSM.
 

 37. 

List and explain 5S.
 

 38. 

List and explain the features that should exist in each quadrant of A3.
 



 
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