wayground logo

Free Printable Worksheets

Font size

S
M
L
XL
Worksheets

QCI LEAN QUESTIONS AND ANSWER

Total questions: 164

Worksheet time: 1hrs 5mins

Name
Class
Date
1.

What is the correct sequence of doing Kaizen in a manufacturing plant where Kabir is the team leader?

a)

Manual then machine then process

b)

Machine then process

c)

Manual and then machine

d)

Process then machine then manual

2.

One of the main purposes of Taguchi's approach was

a)

To reduce the impact due to input variation

b)

Improve quality in production

c)

Improve product functions

d)

Better quality control

3.

Siya learned about Taguchi's method in her statistics class, which was a name given to an application of

a)

Design of experiments

b)

Process Quality control

c)

Setting specification limits

d)

Corrective action method

4.

In the Quality Engineering approach, Nikita focused on developing

a)

Stable process

b)

Robust production technology

c)

Select better manufacturing technology

d)

Reduce rejections

5.

When the rate of throughput goes up within the existing operating expense at Vanya's bakery, we call this

a)

Efficiency

b)

Productivity

c)

Labour productivity

d)

Gross margin increase

6.

Saisha is working on a project and wants to improve her productivity. She believes that productivity is something that

a)

Takes you faster towards your goal

b)

Increases your output

c)

Increases efficiency

d)

Increases Quality

7.

Rahul believes that productivity measures should drive the increase of

a)

Throughput

b)

Output

c)

Reduces cost

d)

Batch size

8.

Aanya is analyzing the productivity of her bakery. She wants to determine the most appropriate formula for productivity. What should she use?

a)

Throughput/Operating expenses

b)

Sales/ No of workers

c)

Sales/Operating expenses

d)

Inventory turns

9.

What is one of the key aspects of TPS?

a)

It is easy to implement

b)

Requires very little management intervention

c)

Can be used in any production environment

d)

It improves production very quickly

10.

Why do Ishaan and Kiara practice lean principles in their manufacturing project?

a)

To increase flow

b)

To improve efficiency

c)

To increase quality

d)

To improve production quantities

11.

Lean is applicable in repetitive production where

a)

Volumes are low and variety high

b)

High volume production

c)

Where product life cycles are small

d)

Customer satisfaction is very high

12.

Avani's business implemented Lean principles, which had a direct impact on

a)

Cash flow

b)

Profit

c)

ROI

d)

All of these

13.

What is the causal relation between 3M in Aarav's project?

a)

Mura leads Muri leads Muda

b)

Muda leads Muri and Mura

c)

Mura and Muda lead to Muri

d)

Muda leads to Mura leads to Muri

14.

How do Mura and Muri impact the production system?

a)

The variability due to Mura and Muri impacts flow

b)

They cause unplanned loads

c)

They only impact planning

d)

They do not impact output

15.

If a system at Ishika's manufacturing plant has high Mura and Muri

a)

It will need excess capacity to maintain required throughput

b)

Cost of operation will be low

c)

Large safety stock will be needed

d)

Better planning methods will be needed

16.

When Mura and Muri are uncontrolled in Tisha's manufacturing process

a)

The system does not recover from loss of output

b)

Requires management intervention

c)

Shop floor requires better management

d)

Quality of products suffers

17.

In a manufacturing company, Vanya is trying to identify the 7 wastes in their production process. She learns that of all the wastes, one form is considered the worst. Which waste is it?

a)

Correction

b)

Motion

c)

Inventory

d)

Overproduction

18.

In a manufacturing plant, Ishika is trying to find a way to reduce overproduction. Which tool should she consider using?

a)

Kanban system

b)

SMED

c)

5S

d)

7 QC tools

19.

Tara is organizing a school event and wants to eliminate wasteful practices. She learns about different types of Muda. Which type of Muda can be easily removed?

a)

Type 1

b)

Type 2

c)

Type 3

d)

Type 4

20.

Aanya is working in a manufacturing plant and wants to improve the efficiency of her team by reducing unnecessary movements during the assembly process. Which tool will be useful in the elimination of waste of motion?

a)

SMED

b)

SQC

c)

5S

d)

U cell layout

21.

Divya is analyzing the benefits of high OTIF in her logistics company. Which of the following is a benefit of high OTIF?

a)

Reduced shipping costs

b)

Improved supply chain efficiency

c)

Increased customer loyalty 

d)

All of the above

22.

Akhil is working on a project to improve the efficiency of his school's recycling program. He believes that by making small, continuous changes, he can enhance the program's effectiveness over time. What is the core idea of Kaizen?

a)

To achieve perfection

b)

To make incremental improvements

c)

To reduce waste

d)

To increase efficiency

23.

Aanya is studying business management and comes across the term VUCA in her coursework. She learns that it is used to describe the challenging environment in which organizations operate today. What does VUCA stand for?

a)

Volatility, Uncertainty, Complexity, Ambiguity

b)

Velocity, Uncertainty, Complexity, Ambition

c)

Volatility, Uncertainty, Change, Ambiguity

d)

Velocity, Uncertainty, Change, Ambiguity

24.

Aashi is leading a team in a rapidly changing market characterized by volatility, uncertainty, complexity, and ambiguity (VUCA). Which of the following is a key skill for Aashi as a leader in this environment?

a)

Rigidity and inflexibility 

b)

Agility and adaptability

c)

Resistance to change

d)

Focus on routine tasks

25.

What is demand in lean

a)

which have quantity and code

b)

which have item code, Quantity and Time

c)

which  Indicates Quantity

d)

none of the above

26.

Aarush is studying supply chain management and wants to understand its primary goal. He learns that it involves coordinating various activities to ensure that products are delivered to customers efficiently. What is the primary goal of supply chain management?

a)

To reduce costs

b)

To improve quality

c)

To increase efficiency and meet customer demand

d)

To minimize inventory levels

27.

Eshaan is working on a project to improve the efficiency of his company's supply chain. He wants to implement a system that uses technology to share data and coordinate activities among supply chain partners. What is the term for this approach?

a)

Supply chain visibility

b)

Supply chain integration

c)

Supply chain optimization

d)

Supply chain automation

28.

What is lead time

a)

The time it takes to complete a process 

b)

The time between ordering and receiving materials

c)

The time between customer order and delivery

d)

The time spent on a specific task

29.

Aashi runs a bakery and has produced too many loaves of bread for the day. What is a consequence of overproduction?

a)

Increased customer satisfaction

b)

Reduced inventory costs

c)

Improved resource utilization

d)

Excess inventory and waste

30.

What is the impact of overproduction on the environment?

a)

Reduced waste

b)

 Increased recycling

c)

Conservation of resources

d)

Excess waste and resource consumption

31.

Ishika is planning a community event for her school. What is the primary purpose of planning?

a)

To ensure execution

b)

To identify goals and objectives

c)

To allocate resources

d)

To monitor progress

32.

In a school project, Sneha and Ishaan are tasked with evaluating the quality of their team's performance. What is the primary purpose of quality measures?

a)

To evaluate performance

b)

To improve processes

c)

To reduce costs

d)

To increase productivity

33.

In a manufacturing plant, Ishika is trying to implement a new process to minimize the time it takes to set up machines for different production runs. What is this technique called?

a)

A lean manufacturing technique to reduce setup times

b)

A quality control methodology

c)

A supply chain management tool

d)

A production scheduling system

34.

In a manufacturing plant, Kabir is tasked with improving the efficiency of the production line. He decides to calculate OEE to better understand how well the equipment is performing.

a)

To identify equipment failures

b)

To optimize production scheduling

c)

To evaluate equipment performance and identify areas for improvement

d)

To reduce maintenance costs

35.

Asher is trying to improve the efficiency of his factory's production line. Which of the following is a key principle for optimizing the flow of materials?

a)

Push production

b)

Pull production

c)

Daily production

d)

Batch production

36.

In a busy restaurant, Aditi notices that the kitchen staff uses visual signals to indicate when they need more ingredients to prepare dishes. What is the term for these visual signals used to trigger material replenishment?

a)

Kanban

b)

Standardized work

c)

Heijunka

d)

Kaizen

37.

In a manufacturing company, Krish is tasked with implementing Heijunka to optimize their production process. What is the primary goal of Heijunka?

a)

To reduce inventory levels

b)

To improve production efficiency

c)

To level production volume and mix

d)

To increase product variety

38.

Ria is working in a manufacturing plant where they implement Jidoka principles. What is the benefit of Jidoka?

a)

Increased efficiency 

b)

Improved quality

c)

Reduced labor costs

d)

Enhanced human-machine collaboration

39.

In a manufacturing plant, Arjun notices that the production schedules are not consistent, leading to some days with too much work and others with too little. Which of the following is an example of "Mura"?

a)

Producing defective products

b)

Overproducing items 

c)

Uneven production schedules

d)

Inefficient use of resources

40.

In a busy manufacturing plant, Kavya noticed that the workers were often pushed to their limits, leading to exhaustion and mistakes. Which of the following is a consequence of "Muri"?

a)

Reduced productivity

b)

Increased quality

c)

 Improved safety

d)

 Decreased employee morale

41.

Siya is working on a project to streamline the production process at her company. What is the purpose of a Value Stream Map (VSM)?

a)

To identify waste

b)

To improve efficiency

c)

To increase productivity

d)

 To visualize the flow of value

42.

Aarav is running a bakery and notices that he is producing more pastries than he can sell each day. What is an example of Overproduction waste?

a)

Producing more than what is needed

b)

Producing less than what is needed

c)

Producing just in time

d)

Producing with defects

43.

Arnav is analyzing the cash flow of his new café. What is cash flow velocity?

a)

The speed at which cash flows into a business

b)

The speed at which cash flows out of a business

c)

The rate at which cash is generated and used within a business

d)

The amount of cash held by a business

44.

What happens to ROI when cash velocity increases?

a)

It decreases

b)

 It remains the same

c)

 It increases

d)

It becomes irrelevant

45.

Akhil is trying to determine the optimal batch size for his bakery to ensure that he meets customer demand without overproducing. What is the purpose of determining batch size?

a)

To minimize production costs

b)

To maximize production efficiency

c)

To optimize inventory levels

d)

To balance production capacity and demand

46.

Naira is working on a project that requires her to assess the production capabilities of her team. What is the primary purpose of Rough Cut Capacity Planning (RCCP) in this context?

a)

Detailed scheduling

b)

Resource allocation

c)

High-level capacity feasibility assessment

d)

Demand forecasting

47.

Tisha is studying the production process of a factory and learns about the four elements of throughput time. What are they?

a)

Transportation, Processing, Inspection, and Delay

b)

Production, Quality, Logistics, and Inventory

c)

Supply, Manufacturing, Delivery, and Returns

d)

Design, Testing, Packaging, and Shipping

48.

In a manufacturing company, Neha is trying to identify different types of waste in their production process. She learns about Type Two Muda, which refers to certain activities that are not adding value but are still part of the process. What is Type Two Muda?

a)

Non-value-added activities that are necessary for the process

b)

Value-added activities that are essential for the process

c)

Non-value-added activities that can be eliminated immediately

d)

Activities that are unnecessary and can be eliminated

49.

Sneha is managing a warehouse for a clothing company. What are the consequences of overproduction waste?

a)

Increased inventory costs, excess storage needs, and potential obsolescence

b)

Decreased inventory costs, reduced storage needs, and improved quality

c)

Improved customer satisfaction, increased sales, and reduced lead times

d)

Reduced production costs, improved efficiency, and enhanced quality

50.

Nikita is analyzing the production process at her factory. She wants to monitor the processes over time to correct deviations and prevent defects. Which 7 QC Tool should she use?

a)

Control Chart

b)

Histogram

c)

Scatter Diagram

d)

Pareto Diagram

51.

What is the main intent of Poka-Yoke

a)

Error-proofing

b)

Quick processing

c)

Better Quality

d)

Visual control

52.

Poka -Yoke is the practice that helps in

a)

Zero defect approach

b)

Six sigma

c)

SQC

d)

Quality control

53.

Poka Yoke provides

a)

Judgement inspection

b)

Informative inspection

c)

Zero inspection

d)

No inspection

54.

Statistical Quality control techniques provides

a)

Judgement inspection

b)

Informative inspection

c)

Process control capability

d)

Remove inspection

55.

What is the purpose of VSM

a)

To identify waste

b)

To add value

c)

To create value

d)

To do load levelling

56.

Value is created during 

a)

Manufacturing

b)

Inspection

c)

Waiting

d)

All of the above

57.

VATI classification uses the point of view of

a)

Flow of material

b)

Plant layout

c)

Size of production facility

d)

Product manufacturing capability

58.

If divergence is dominant

a)

V Plant

b)

A Plant

c)

T Plant

d)

I Plant

59.

If convergence is dominant

a)

A Plant

b)

T Plant

c)

V Plant

d)

I Plant

60.

If both convergence and divergence

a)

T Plant

b)

A Plant

c)

V Plant

d)

I Plant

61.

I neither convergence nor divergence

a)

I Plant

b)

A Plant

c)

T Plant

d)

V Plant

62.

Finished good inventory is high in

a)

V Plant

b)

A Plant

c)

T Plant

d)

I Plant

63.

The technique to reduce setup change time is

a)

Quick change over technique

b)

Single minute exchange of die

c)

Total presventive maintenance

d)

Total Quality control

64.

In SMED One of the key steps in separation of 

a)

Internal setups and external setups

b)

Designing special tools

c)

Automation

d)

Designing multipurpose tools

65.

External setup means

a)

Work done while machine is operating

b)

Work done outside the factory

c)

Machine is scheduled for change over

d)

Work done externally when machine is stopped

66.

SMED says eliminate 

a)

Rework

b)

Adjustments

c)

Setups

d)

Keeping spares

67.

SMED conceptual stage which comes earliest

a)

Streamlining external seup operation

b)

Converting internal to external setups

c)

Separating internal and external setups

d)

Performing system checks

68.

SMED strives to standardise

a)

Form

b)

Function

c)

Size 

d)

Weight

69.

Andon means

a)

Automatic stopping machine

b)

Visual control

c)

Quality control

d)

Auto loading

70.

Why is Andon used

a)

To identify machine status from distance

b)

To identify if the machine is working

c)

To identify if the worker at the machine

d)

None of the above

71.

One of the main use of Andon is to 

a)

Signal when there is a problem

b)

Call the manager

c)

To notify material shortage 

d)

None of the above

72.

What is the purpose of DWM

a)

Policy deployment in shop floor

b)

Improving 5S

c)

Motivating employees

d)

Quality management 

73.

Andon can be specially designed to intimating

a)

Break down

b)

Quality issues

c)

Setup progress

d)

All of the above

74.

DWM is a tool for improving in shop floor is

a)

Quality

b)

Communication

c)

House keeping

d)

Attendance

75.

On shop floor DWM reduces 

a)

Management time

b)

Rejection

c)

Setup time

d)

Break down

76.

DWM is a practice which allows

a)

Self governing on shop floor

b)

The shop floor to know what management wants

c)

Cost reduction

d)

Supervisor to control better

77.

DWM should improve

a)

Visual control

b)

Employee involvement

c)

Delivery performance

d)

All of the above

78.

This is Distinguishing between necessary and unnecessary things and getting rid of what you do not need.

a)

Sort

b)

Sustain

c)

Standardize

d)

Set in order

79.

What is the English equivalent of the Japanese word ‘Seiton’?

a)

Sorting out

b)

Systematic arrangement

c)

 Standardizing

d)

 Self-discipline

80.

What is the English equivalent of the Japanese word ‘Seiso’?

a)

Sorting out

b)

Systematic arrangement

c)

Scrub, shine, sweep

d)

Self-discipline

81.

What are the 5 phases of 5S?

a)

Shine, Shut-Up, Sustain, Sort, Standardize

b)

 Sustain, Sort, Standardize, Sushi mi, Shine

c)

Sort, Set in order, Shine, Standardize, Sustain

d)

Sort, Sustain, Sushi, Shine, Standardize

e)

Shine, Standardize, Sustain, Set-In-Order, Salami

82.

Which of these benefits of 5S are of value to your company?

a)

Improved employee morale

b)

Improved safety

c)

Increased productivity

d)

Increased profitability

e)

All of the above

83.

What is the best description of Value Adding Activity?

a)

Activity that adds value to the product in the eyes of customer

b)

Activity that adds value to the product in the eyes of manufacturer

c)

Activity that requires valuable resources

d)

All the above 

84.

VSM is a lean tool and its main purpose is 

a)

Reducing tool change and toll setting time 

b)

Understanding the process ( Material and information flows) and improving  

c)

Implementing 5S to improve workplace 

d)

Reduce rejection

85.

Which diagram is NOT a part of value stream mapping? 

a)

Current state drawing 

b)

Future state drawing 

c)

Process flow diagram

d)

 Implementation plan

86.

Which letter from a VATI analysis would most likely represent the flow of material through the production process of manufacturing an orbital satellite?

a)

A Plant

b)

I Plant

c)

V Plant

d)

T Plant

87.

Which tool is also known as  80-20 Rule

a)

Histogram

b)

Pareto diagram

c)

Cause and effect diagram

d)

Scatter diagram

88.

The cost  rework in a product Quality cost system is categorized as

a)

Internal failure cost

b)

Prevention cost

c)

External failure cost

d)

Appraisal costs

89.

Cost of Quality is given by costs of 

a)

 Prevention + Appraisals

b)

 Internal failure + external failure 

c)

Prevention + Appraisals + Internal failure + External failure

d)

Appraisals + Internal failure

90.

Two variables, x and y, are related. Variable x increases or decreases with y. Which of the following tools could best be used to graphically show this relationship?

a)

Histogram

b)

Control Charts

c)

Pareto diagram

d)

Scatter Plot

91.

Which tool recognizes the relationship between potential causes and an effect or a problem. 

a)

Flow chart

b)

Fish bore diagram 

c)

Pareto chart

d)

Histogram 

92.

Types of Poka Yoke are 

a)

Warning type

b)

Controlling type

c)

Both  A and B

d)

None of the above

93.

In Lean Terminology, what does Waste mean?

a)

Part of any activity which is inevitable

b)

Part of activity when operator is idle

c)

Rejection of material because of quality related problems

d)

Anything in the process that does not add value from the customer's perspective.

94.

Fish bone diagram is also known as 

a)

Ishikawa diagram

b)

Cause and effect diagram

c)

Both A and B

d)

None of the above

95.

The tool used to show movement of product is:

a)

Histogram

b)

Control chart

c)

Process flow chart

d)

Scatter diagram

96.

Pareto diagram is named after ________

a)

Vilfredo Pareto

b)

William Deming

c)

Joseph Juran

d)

Philip Crosby

97.

Who formalized the concept of Poka-yoke?

a)

Dr. Shigeo Shingo

b)

Deming

c)

Crosby

d)

Juran

98.

Which of the following is considered value-added work, rather than waste 

a)

Carrying the part to painting area.

b)

Painting part

c)

Repairing defective part

d)

All the above

99.

From The 7 QC tools which is to investigate the correlation of data?

a)

 Scatter Diagram

b)

Check Sheet

c)

Cause and Effect Diagram

d)

Histogram

100.

What do Yokeru and Poka mean respectively?

a)

Avoid, inadvertent errors

b)

Inadvertent errors, avoid

c)

 Inadvertent mistakes, avoid

d)

Inadvertent errors, inadvertent mistakes

101.

What is the primary focus of Lean manufacturing?

a)

Minimizing waste

b)

Enhancing employee satisfaction

c)

Maximizing production speed

d)

Increasing product variety

102.

Which of the following is a key principle of Just-In-Time (JIT) production?

a)

Standardizing processes

b)

Producing in large batches

c)

Reducing lead times

d)

Increasing inventory levels

103.

What is the main purpose of a value stream map?

a)

To manage supplier relationships

b)

To calculate production costs

c)

To track employee performance

d)

To visualize the flow of materials and information

104.

Which of the following are NOT examples of Poka Yoke (mistake proofing)?

a)

Elevator doors sensing when someone is in the doorway to prevent people from getting crushed.

b)

Machine guards prevent people from reaching into dangerous machinery.

c)

Designing of 3 pin electrical plug to prevent wrong connection

d)

Operators following safety standards

105.

MSME Competitive (Lean) Scheme is having two phases. Phase 1 is mainly focusing on For Manufacturing MSMEs. Phase 2 focuses on Inclusion of Service Sector MSMEs*

a)

TRUE

b)

FALSE

c)

Not any

106.

UDYAM Registration is a not a must requirement for registering under MSME Competitive (Lean) Scheme   *

a)

TRUE

b)

FALSE

107.

Under MSME Competitive (Lean) scheme all type of industries can be registered

a)

TRUE

b)

FALSE

108.

Under MSME Competitive (Lean) scheme only MSMEs can be registered.*

a)

TRUE

b)

FALSE

109.

Participation in MSME Competitive (Lean) scheme does not affect the profitability of the MSME*

a)

TRUE

b)

FALSE

110.

The objective of the MSME Competitive (Lean) scheme is to enhance the Domestic and Global Competitiveness of MSMEs through the application of various Lean Techniques and Tools    

a)

TRUE

b)

FALSE

111.

MSME Competitive (Lean) Scheme can be attained in three Levels after registering and taking the Lean Pledge 

a)

TRUE

b)

FALSE

112.

MSME Competitive (Lean) Scheme have three levels, Level 1: BASIC, Level 2: INTERMEDIATE and Level 3: ADVANCED 

a)

TRUE

b)

FALSE

113.

MSME Competitive (Lean) Scheme have two levels LEAN, Level 1: BASIC, Level 2: and INTERMEDIATE    

a)

TRUE

b)

FALSE

114.

In MSME Competitive (Lean) Scheme, Level 1: BASIC is implemented through self On Line Learning    

a)

TRUE

b)

FALSE

115.

MSME Competitive (Lean) scheme results in

a)

Reduction in Rejection

b)

Optimization of Space in shop floor

c)

Work place Safety

d)

All of above

116.

MSME Competitive (Lean) scheme results in

a)

Reduction in Rejection

b)

Securing environmental clearances from central and state governments

c)

Reduction in accidents on city roads

d)

All of above

117.

MSME Competitive (Lean) scheme results in

a)

Customer satisfaction

b)

Knowledge and skill set of employees

c)

Innovative work culture

d)

All of above

118.

MSME Competitive (Lean) Scheme have 

a)

Two levels LEAN, Level 1: BASIC, Level 2: INTERMEDIATE

b)

Three levels, Level 1: BASIC, Level 2: and INTERMEDIATE and Level 3: ADVANCED

c)

One level: BASIC

d)

Four levels, Level 1: BASIC, Level 2: INTERMEDIATE Level 3: ADVANCED Level 4: SUPER ADVANCED

119.

In MSME Competitive (Lean) scheme following companies can be registered

a)

Micro MSMEs

b)

Small MSMEs

c)

Medium MSMEs

d)

All of above

120.

What are the major reason(s) the Japanese place such a high emphasis on housekeeping items in the 5S approach?                          

I.     They figure that workplace organization and manufacturing are inseparable

II.    They recognize that workplace organization must precede other high levels of performance

III.  The Japanese tend to be a nation of tidy people

a)

a. I only

b)

b. I and II only

c)

c. II and III only

d)

d. I, II and III

e)

I,II,III

121.

The visual factory would be supported to the greatest extent by:

I.       Muda

II.     Kanban

III.    Gemba IV. 5S

a)

a. I and II

b)

b. II and III

c)

c. II and IV

d)

d. lll and IV

122.

Considering that all of the following terms have benefits, which would LEAST likely ailed product quality?

a)

Muda

b)

5S

c)

Lean Manufacturing

d)

Total Productive Maintenance

123.

Standard work relies most heavily on which three tools?

I.       Visual factory

II.     5S                         

III.    Kanban

IV.    EWMA (Exponentially Weighted Moving Average)

a)

a. I, II and Ill

b)

b. I, II and IV

c)

c. I, lll and IV

d)

d. II, III and IV

124.

Overproduction, scrap, waiting, and excess motion are all forms of:

a)

TPM

b)

Muda

c)

Kanban

d)

CFM

125.

The tool/technique most widely used by a number of automotive manufactures that supply products to Toyota on demand is called

a)

Kanban

b)

Muda

c)

Poka-yoke

d)

An Andon board

126.

Which of the following Japanese techniques is most clearly identified with small incremental change?

a)

Kaizen

b)

Kanban

c)

Poka-yoke

d)

5S strategy

127.

Goldratt's theory of constraints deals with money in relationship to three fundamental measurements for evaluating a system. Align the following measures with their monetary equivalents.

       

a)

I - C, II - B, Ill - A

b)

I - B, II - A, Ill - C

c)

I - A, II - B, Ill - C

d)

I- B, II - C, Ill - A

128.

Which of the following are goals of TOC?

I.             Increased throughput

II.           Reduced inventory

III.          Reduced operating expenses

IV.          Capacity balanced with demand

a)

I, II and III only

b)

I, II and IV only

c)

II, Ill and IV only

d)

I, II, III and IV

129.

Listed below are the seven most widely recognized forms of Muda or non-value added activities.

I.    Overproduction           

II.    Inventory           

III.  Repair/reject 

IV   Motion

V.   Processing

VI.  Waiting

VII. Transport

Which two of the above are least likely to result in poor product quality?

a)

I and II only

b)

III and V only

c)

IV and VI only

d)

VI arid VII only

130.

If one were to characterize the ground breaking work of Womack, in introducing the term Lean Production to the Western world, in one word, that word would be:

a)

Muda

b)

Distance

c)

Value

d)

Rhythm

131.

Identify a non-value added activity that would be considered a form of processing Muda:

a)

Any and all forms of transportation

b)

An ergonomically sound workplace

c)

Reshaping a product due to poor dies

d)

Producing exact quantity needed by the customer

132.

Which of the following conditions are driving companies to adopt a lean approach?

I.        Higher performance requirements

II.        Eliminating waste from the process

III.      Reducing total costs

IV.      Increasing capacity

a)

I and IV only

b)

II and III only

c)

I, II and IV only

d)

I, II, III and IV

133.

When the term pull is used in lean thinking. Who is ultimately doing the pulling?

a)

Downstream operations

b)

The Takt Time

c)

The Customer

d)

The Cycle Time

134.

Which of the following would be a device associated with the visual factory?

a)

Standard work

b)

Andon board

c)

Queue time

d)

Work cell

135.

What is the best definition of takt time?

a)

It is a calculated time element that equals customer demand

b)

It is the speed at which parts must be manufactured in order to satisfy the Demand

c)

It is the heartbeat of any Lean System

d)

It is the application of Kaizen to continuous flow Manufacturing

136.

Lean Tenets and techniques that best compliment the visual factory concept are:

 I.      Kanban                 III.   5 -Whys

II.    Poka-yoke            IV.   5 - S's

a)

I, II, and III only

b)

I, Ill, and IV only

c)

I, II, and IV only

d)

II, III, and IV only

137.

One would say that the Kanban method would be most closely associated with

a)

The elimination of non-value added activities in the process

b)

The development of a future state process stream map

c)

Making problems visible in a process, thus clarifying targets for improvement

d)

The control of material flow

138.

Poka-yoke uses a number of devices to mistake proof a process.  Which of the following would least likely be included?

a)

Fixture templates

b)

Electric switches

c)

Buzzer or light signals

d)

Self-check inspections

139.

Just in time (JIT) is collectively characterized by:

I.      Producing the right items

II.    Delivering the right items

Ill.   In the right amounts

IV.   At the right time

a)

I and III only

b)

I, II and IV only

c)

II and III only

d)

I, II, Ill and IV

140.

In the SMED system what is the real meaning of the single minute concept?

a)

That dies will be exchanged in 1 minute or less

b)

That dies will be exchanged in less than 5 minutes

c)

That dies will be exchanged in less than 10 minutes

d)

That dies will be exchanged in less than 15 minutes

141.

Lean thinking advocates that "up-stream" activity should create a "pull" effect, not a "push" effect

a)

TRUE

b)

FALSE

142.

Lean thinking advocates that decision making should be elevated to the highest levels of an organization

a)

TRUE

b)

FALSE

143.

Lean thinking is concerned with the elimination of non-value added activity. 

a)

TRUE

b)

FALSE

144.

Root cause analysis is not related to PokaYoke. 

a)

TRUE

b)

FALSE

145.

A PokaYoke system is closely related to mistake-proofing and defect prevention

a)

TRUE

b)

FALSE

146.

A core belief underlying PokaYoke is: When people work together, zero defects is possible

a)

TRUE

b)

FALSE

147.

Theory holds that if the 6S system is properly implemented, quality will naturally improve

a)

TRUE

b)

FALSE

148.

The 6S system is partly based on the benefits of sound "housekeeping" principles

a)

TRUE

b)

FALSE

149.

The 6S system involves sorting, straightening, scrubbing, safety, standardizing, and sustaining. 

a)

TRUE

b)

FALSE

150.

The concept of "complexity" is directly related to the 7W approach

a)

TRUE

b)

FALSE

151.

The 7W approach is concerned with waste

a)

TRUE

b)

FALSE

152.

The idea of "overproduction" is not a part of the 7W approach to improvement

a)

TRUE

b)

FALSE

153.

The 6Ms are major "families" of possible causation

a)

TRUE

b)

FALSE

154.

The 6M approach to problem solving can be enabled by using a fishbone diagram

a)

TRUE

b)

FALSE

155.

The 6M approach is based on the analysis of process capability data

a)

TRUE

b)

FALSE

156.

The Material, Methods, Machines, Manpower, Management focused approach to problem solving can be enabled by using a fishbone diagram

a)

TRUE

b)

FALSE

157.

The 3Ms - Muda, Mura, Muri approach is based on the analysis of process capability data

a)

TRUE

b)

FALSE

158.

Which of these is an advantage of single piece flow over batch processing?

a)

It cuts the elapsed time between customer’s order and shipment of the order

b)

It reduces inventory, labor energy and space required by batch and queue processing

c)

It enables detection of quality problems early in the process

d)

All of the above

159.

In a fishbone cause and effect diagram, what does the central spine represent?

a)

Secondary causes

b)

Major cause

c)

Major effect

d)

None of the above

160.

Which of the following statements is FALSE?

a)

Kaizen is focused on small improvements as a result of ongoing efforts and innovation is focused on large, dramatic improvements as a result of big changes

b)

Kaizen is a continuous process while Innovation is intermittent

c)

Kaizen follows an approach of collectivism while Innovation has an approach of individualism

d)

Change through Kaizen is volatile while change through innovation is gradual and constant

161.

Which of the following is NOT a safety PPE (Personal Protective Equipment) in a manufacturing MSME?

a)

Safety Helmet

b)

Safety goggles

c)

Safety shoes

d)

Safety Horn

162.

Which of the following is the focus of statistical process control?

a)

Determining the efficiency of an operations system

b)

Measuring the amount of re-work required to rectify faulty goods

c)

Identifying the security needs of an operations system

d)

Measuring and controlling process variations

163.

Cause and Effect Diagram is  known as

a)

Ishikawa Diagram

b)

4-M

c)

Affinity Diagram

d)

None of the above

164.

One of the purposes of using a fishbone diagram is to:

a)

Separate a problem into smaller components

b)

Identify and classify sources of variations into major groups

c)

Define the problem in sequential order

d)

Show the relationship between parameters