Lean

Who invented the “5 Why” technique, a method used to determine the root cause of problems?

• Taiichi Ohno in the 1950s

• Shigeo Shingo in the 1970s

• Masaaki Imai in the 1980s

• Sakichi Toyoda in the 1930s

• W. Edwards Deming in the 1940s

Lean manufacturing, who were the key figures involved in its development?

• Henry Ford and Frederick Taylor, starting in 1923

• IBM; Masaaki Imai and W. Edwards Deming, starting in 1955

• Toyota; Taiichi Ohno and Eiji Toyoda, starting in 1948

• Honda; Shigeo Shingo and Kaoru Ishikawa, starting in 1965

• General Electric; Bill Smith and Michael Porter, starting in 1980

Who is credited with coining the term “Lean” to describe Toyota's production system in the late 1980s?

• Taiichi Ohno

• Eiji Toyoda

• Masaaki Imai

• John Krafcik

• Shigeo Shingo

Answer explanation

John Krafcik, a researcher at MIT, first used the term "Lean" in his 1988 article to describe Toyota’s efficient, waste-reducing production system. His work helped popularize Lean principles outside of Japan and introduced them to a global audience.

In the context of Lean, what does the term “Kaizen” mean?

• Big changes

• Continuous improvement

• Quality control

• Lean planning

• Process mapping

The "Fishbone Diagram" was created by whom and when?

• Shigeo Shingo in 1955

• Kaoru Ishikawa in 1960

• Sakichi Toyoda in 1935

• Masaaki Imai in 1980

• Taiichi Ohno in 1975

Answer explanation

Kaoru Ishikawa, a Japanese organizational theorist and quality management expert, developed the Fishbone Diagram in 1960. Ishikawa was known for his work on quality control processes, and his diagram helped visualize causes of problems, greatly enhancing problem-solving techniques.

In which industry did Lean principles first find widespread application outside of manufacturing?

• Retail

• Healthcare

• Banking

• Agriculture

• Education

Answer explanation

Lean principles found early success in healthcare as hospitals and clinics began using Lean to streamline operations, reduce wait times, and improve patient outcomes. Lean’s emphasis on eliminating waste and improving flow proved highly valuable in enhancing healthcare quality and efficiency.

What is “Muda” in Lean terminology?

• Quality improvement

• Employee engagement

• Inventory management

• Customer satisfaction

• Waste

Answer explanation

"Muda" is a Japanese term used in Lean to refer to waste or any activity that does not add value. Eliminating Muda is essential in Lean as it directly contributes to cost savings and improved productivity.

In Lean, what does the term “Gemba” mean?

• Defect

• The real place

• Flow

• Inventory

• Supplier

Answer explanation

Gemba is a Japanese term meaning "the real place," referring to the area where work happens. Lean encourages leaders to visit the Gemba to understand processes, identify issues, and make improvements at the source.

Who developed the A3 problem-solving process, and in which decade did it originate?

• Eiji Toyoda in the 1970s

• Shigeo Shingo in the 1980s

• Sakichi Toyoda in the 1930s

• Toyota engineers in the 1960s

• Kaoru Ishikawa in the 1950s

Which U.S. company was one of the earliest adopters of Lean methodology outside Japan, focusing on quality improvement and defect reduction?

• General Electric

• Motorola

• Ford

• IBM

• Apple

Answer explanation

Motorola was an early adopter of Lean principles in the 1980s, integrating them with their own Six Sigma methodology to improve quality control and reduce defects. This combination set a new standard for quality management across various industries.