16/1&2 MCQs on Continuous Improvement and Lean Manufacturing

What does continuous improvement (Kaizen) focus on?

• Making large, one-time changes to processes

• Making small, incremental changes to improve performance

• Reducing the number of employees in a company

• Increasing production without considering efficiency

Why doesn’t real manufacturing performance achieve 100% efficiency?

• Equipment may be outdated or unavailable

• Different products require different setups

• Poor maintenance of workspaces and tools

• All of the above

What is the primary goal of lean manufacturing?

• Increase the number of workers in production

• Reduce non-value-added activities and lower costs

• Increase inventory levels to prevent shortages

• Reduce the number of products being made

Which of the following is NOT one of Toyota’s 8 Wastes (TIMWOODS)?

• Overproduction

• Motion

• Waiting

• Automation

Why is excess inventory considered a waste?

• It takes up space and increases storage costs

• It helps production run faster

• It ensures materials are always available for production

• It reduces lead time for new orders

What is a key strategy to reduce waiting waste in production?

• Stockpile finished goods in large quantities

• Ensure materials flow directly from one process to another

• Have workers take longer breaks to reduce downtime

• Increase the number of quality checks

What is overprocessing in manufacturing?

• Producing more products than needed

• Using unnecessary steps or higher precision than required

• Not producing enough products to meet demand

• Failing to inspect products properly

How can the waste of unused talent be minimised?

• Assign workers only to repetitive tasks

• Limit communication between management and employees

• Involve employees in process improvements

• Increase automation to reduce human involvement

What does the acronym TIMWOODS help to remember?

• The key principles of automation

• The different types of manufacturing equipment

• The 8 types of waste in lean manufacturing

• The main benefits of continuous improvement