sigma sundar, your score was 60%.

Which of the following is TRUE about Lean Thinking?

A. Applies universal principles
B. Focuses on the whole
C. Is based on the tried and true
D. All of the above

Correct!

Which of the following is NOT true about Lean Thinking?

A. Applies 5 principles
B. Can be applied anywhere
C. Has been around for 25 years
D. Saves a company money

Wrong! You answered: A

Which of the following are authors of the book entitled "Lean Thinking"
mentioned in this course?
A. Fred Penner Dan Jones
B. James Wall and Don Juan
C. Jim Womak and Dan Jones
D. Jim Womak and David James

Correct!

Lean trains people to see things in a different light and changes their
way of __________.
A. Communicating
B. Thinking
C. Resting
D. None of the above

Correct!

When making improvements it is best to focus on the __________.

A. Parts
B. Department
C. Issue
D. Whole

Wrong! You answered: C

Lean utilizes universal principles which apply to all sorts of

industries
T

Correct!

Lean principles have been around for 50-60 years, but, North America is

lagging in adopting the thinking

T

Wrong! You answered: F

Lean principles will not apply to all systems of processes

F

Correct!

Lean looks at why Toyota is the most successful company in the world
and provides 3 principles
F

Wrong! You answered: T

In the hospital wait time example the weak link in the system was a
lack of information
T

Correct!

Challenge Question: Identify and explain the 5 principles of Lean.

VALUE, VALUE STREAMING, PULL, FLOW, TAKT.

Which of the following is not one of the 7 forms of waste?

A. Transportation.
B. Overanalyzing.
C. Unnecessary Inventory.
D. Defects.

Correct!

When overproduction is prevalent in a company a visual indicator of

this is __________.
A. Excessive occurrences of defects.
B. Lower costs for the customer.
C. Large amounts of inventory.
D. Quicker product deliveries.

Correct!

The DELL company's success is largely attributed to their ability to

__________.
A. Produce more than the customer demand.
B. Produce less than the customer demand.
C. Produce according to a projected demand.
D. Produce according to customer demand.

Correct!

Which of the following is/are an issue with overproducing computers for

sale?
A. The mix is too diverse and it is hard to configure
B. There's never enough parts.
C. Products become obsolete before they can be sold.
D. Both "a" and "c" above are correct.

Correct!

More inventories equates to better __________.

A. Customer service.
B. Production times.
C. Employee relations.
D. None of the above.

Wrong! You answered: A

Overproduction is defined as producing more/sooner than the Internal or

External customer needs.
T

Correct!

Michael Dell's success was based on producing ahead of time and thus
meeting the customer demand.
F

Wrong! You answered: T

The customer cares about quick product delivery and views it as good
customer service.
T

Correct!

It costs money to carry inventory (e.g. for storage costs).

T

Correct!

Most companies do not need to carry a strategic amount of inventory.

F

Correct!

If we know that a customer will request an order to be duplicated in

one month, and we can build the item for less cost if we build them all
at once due to set up times, what is wrong with thought process?
the order is not confirmed, it is just forecasted.

One obstacle to a successful Lean implementation is people's fear of

__________.

A. The Customer
B. The Boss
C. Change
D. None of the above

Correct!

When analyzing the percent of waste within an entire process it is best to

__________.
A. Break the process down into smaller steps.
B. Think of each step as 'verb' starting and action.
C. Determine whether a step is VA or NVA.
D. All of the above.

Correct!

Define each activity within a process as a small step and describe it with a
__________ starting each activity.
A. Verb
B. Noun
C. Adjective
D. Conjunction

Correct!

What percent of activities in an entire manufacturing shop floor add value

from the customer's perspective?

A. 95%
B. 80%
C. 5%
D. 1%

Correct!

When determining what activities add value to a process, always take the
perspective of the __________.
A. Employee.
B. Supervisor.
C. Company.
D. Customer.

Correct!

Customers do not mind waiting for a product or service.

F

Wrong! You answered: T

The percentage of activities that add value in an office environment is 35%.

F

Correct!

The costs of running companies in North America have tended to be

generally higher that in Japan.

T

Correct!

95% of the activities in a manufacturing process are non-value added from

the customer's perspective.
T

Correct!

One obstacle to a Lean implementation is that people prefer their comfort

zones.
T

Correct!

Waste is described as being the biggest obstacle to complete Lean

implementation. Explain this statement.
WASTE IS 95% OF NON-VALUE ACTIVITY WHICH ADDS COST TO A PRODUCT
BY MUDA, MURI, MURA. THIS LEADS TO MORE TIME CONSUMING AND THUS
THE PRODUCT IS NOT DELIVERED AT CUSTOMERS DEMAND.

The waste of waiting can be defined as __________.

A. Periods of inactivity for people.
B. Periods of delay of information.
C. Periods of inactivity for machinery that is required immediately.

D. All of the above

Correct!

When we find out why a customer is waiting we should __________.

A. File the information for future reference.
B. Encourage them to move faster.
C. Do something about it.
D. All of the above.

Wrong! You answered: D

If a retail customer is waiting for support to find an item, then they are
__________.
A. Being serviced in a way that they value.
B. Being withheld from the VA activity of shopping.
C. Both "a" and "b" are correct.
D. None of the above.

Correct!

The best solution to machine breakdowns is to __________.

A. Build in regular maintenance checks.
B. Purchase a new machine to replace it.
C. Repair them quickly each time.
D. All of the above.

Correct!

Machine breakdowns result in the waste of waiting and __________.

A. Bring production to a halt.
B. Cost the company a lot of money.
C. Inactive employees.
D. All of the above.

Correct!

Customer wait time is a given and should be tolerated.

F

Correct!

Removing time out of a process is a clear indicator that improvement was

possible.
T

Correct!

Taking a preventative approach towards machine breakdowns moves us away

from the tendency to ignore warning signs.
T

Correct!

As we try to identify waste of waiting we should remain focused on the

company's perspective.
F

Correct!

Regular maintenance check of machinery is a NVA-but-necessary activity.

T

Correct!

Challenge Question: Several examples highlighting the waste of waiting have

been identified in this section. Can you think of any more? Please list and
describe.
THEORY OF CONSTRAINTS,INVENTRY.

The waste of Transportation is defined as __________.

A. Using the wrong type of vehicle.
B. Moving items that are too heavy.
C. Transporting items sooner than necessary.
D. None of the above.

Correct!

A system designed to show the waste of transportation within a process is

called __________.
A. A transportation diagram.

B. A line graph.
C. A distance table.
D. A spaghetti diagram.

Correct!

In the order form example the document was transported a distance of

__________.
A. Approximately 30 km.
B. Approximately 300 m.
C. Approximately 3 km.
D. None of the above.

Correct!

As you eliminate the waste of transportation from a process __________.

A. You should also increase your batch sizes.
B. You should choose faster methods of travel.
C. You should keep all VA steps.
D. You should take longer breaks.

Correct!

Learning methods that assist in determining whether parts of a process are

VA or NVA are __________.
A. Not important.
B. Necessary to a company's success.

C. A consultant's job.
D. None of the above.

Correct!

The waste of transportation is not visually apparent and is hard to see.

F

Correct!

Excessive movement of people, information or materials is considered a

waste of Transportation.
T

Correct!

One type of map that charts the flow of a product. or a person is called a
spaghetti diagram.
T

Correct!

One way to reduce the waste of transportation is to eliminate the

unnecessary steps within a process.
T

Wrong! You answered: F

Determining whether parts of a process are VA or NVA is a skill only managers

should know.
F

Correct!

Challenge Question: Some transportation is necessary in an operation. When

can transportation be considered a value added step in the process.
IT CAN BE CONSIDERED AS VALUE ONLY WHEN A PRODUCT IS MOVED IN
BETWEEN TWO OPERATIONS.

Inappropriate processing is using the wrong set of __________.

A. Ideas.
B. Tools.
C. Parts.
D. All of the above

Correct!

New hires bring __________ to the workplace.

A. Their experience.
B. New solutions.
C. Fresh eyes.
D. All of the above.

Wrong! You answered: C

We should try and understand all new processes and __________.

A. Implement them without question.
B. Remember that bigger is better.
C. Look for the errors we can correct.
D. None of the above.

Correct!

In the Wal-Mart example George brings to light how __________.

A. We should look for the enemy within.
B. All of us tend to become blind to waste.
C. A machine should be brought closer to the point of use.
D. Cutting 6 inches off the materials was a good solution.

Correct!

The PAL Manufacturing example shows how a company can __________.

A. Use their tools ineffectively.
B. Buy the wrong computer program.
C. Catalogue parts.
D. None of the above

Correct!

Inappropriate Processing is a waste that is hidden to the people that are

doing it.

Correct!

New processes should never be questioned as they are most likely correct.
F

Correct!

Never ask the 'dumb questions' as they do not add value.

F

Wrong! You answered: T

One form of Inappropriate Processing is using the wrong procedures.

T

Correct!

When we uncover waste we should celebrate that we found the problem and
not look to lay blame.
T

Correct!

Challenge Question: Try to find three examples of inappropriate processing in

your organization. Please identify them and explain why they are

inappropriate.

A symptom of Unnecessary Inventory can be a __________.

A. delay of raw materials.
B. company's use of excessive policies and procedures.
C. huge selection of tools to do the work when a single tool is needed.
D. All of the above.

Correct!

Lean encourages activity that __________ the amount of inventory in a

company.
A. Equalizes.
B. Increases.
C. Reduces.
D. Redistributes.

Wrong! You answered: D

Anything above a strategic amount of inventory is deemed __________.

A. Inappropriate.
B. A plus point.
C. Up for sale.
D. Unnecessary

Correct!

The excess amount of inventory is deemed to be __________.

A. An asset.
B. A waste.
C. A safety net.
D. None of the above.

Correct!

Examples of Unnecessary Inventory in retail that were sited were __________.

A. Promo overstocks.
B. Obsolete items.
C. Excessive stock in a bulk bin.
D. All of the above.

Correct!

Most companies are fully aware of their inventory costs.

F

Correct!

A company needs to have a strategic amount of inventory on hand.

T

Correct!

Inventory has a tendency to collect.

T

Correct!

A good answer to the question "How much does inventory cost us today?"
is."Lots".
F

Wrong! You answered: T

When you reduce inventory you are saving money.

T

Correct!

Challenge Question: Often the cost of material is reduced when purchased in

larger quantities. This can provide a cost saving to the company which makes
management happy. Explain why this practice can "Backfire" and actually
cost the company more.
INCREASES INVENTRY COST SO TIME DELAY AND OVERPRODUCTION MAY
OCCUR.

Challenge Question: Often the cost of material is reduced when purchased in

larger quantities. This can provide a cost saving to the company which makes
management happy. Explain why this practice can "Backfire" and actually
cost the company more.

Automation assisted companies by elimating tasks that are __________.

A. Dark, dingy and dangerous
B. Dirty, dingy, and dragging.
C. Dumb, dirty and dangerous.
D. None of the Above.

Correct!

Examples of Unnecessary Motion are __________.

A. Reaching out to get supplies.
B. Bending down to get the tools needed.
C. Moving materials unnecessarily.
D. All of the Above

Correct!

The following are ways that 5S ensures that tools and materials are in the
right spot.
A. The "W" formation (always walk towards your work and then back)
B. The 90 degrees rule (all tools should be within 90 degrees from your nose)
C. The strike zone (all work you do should be between your knees and
shoulder).
D. B and C only

Correct!

Which of the following is the correct order for 5S activities?

A. Sort, Set In Order, Shine, Standardize, Sustain.

B. Standardize, Sort, Set In Order, Shine, Sustain.
C. Standardize, Sort, Shine, Set In Order, Sustain.
D. Sort, Shine, Set In Order, Standardize, Sustain.

Correct!

Which of the following is not a definition of a 5S activity?

A. Clean everything and use cleaning as a method of inspection.
B. Order everything for maximum exposure and availability.
C. Create standards for the first S's and make them obvious through visual
techniques.
D. Sustain the gains through self-discipline and training.

Correct!

Any motion that does not add value to the product or process is a waste.
T

Correct!

Approximately 20% of companies that start with 5S.stay with 5S.

F

Correct!

5S is a workplace organization system that has proven very effective.

Correct!

The second S is Sort and means to sort through all items and sort out those
unneeded.
F

Correct!

The easiest S to achieve is Sustain.

F

Correct!

Challenge Question: Can you identify any examples of the "Unnecessary

Waste of Motion" in your organization.
HAVING CANTEEN AND WASHPLACE AT LONG DISTANCE FROM GEMBA.

A poor practice for any company is to __________.

A. flush out the wastes within a system
B. try to do things right the first time
C. use low tech solutions for low tech problems
D. make things more complex than they need to be

Wrong! You answered: A

The waste of Complexity implies that things are more __________ than they
need to be.
A. simple
B. complicated
C. clear
D. standardized

Correct!

Not getting the ideas out of the people that work in an area is an example of
__________.
A. the waste of Complexity
B. keeping it simple
C. the waste of Untapped Human Potential
D. "a" and "c" are correct

Wrong! You answered: D

In the before and after pictures used, an improvement item was __________.
A. the walls were painted
B. inventory was reduced
C. motion was reduced
D. all of the above

Correct!

In the before picture, having the wrong tube and shaft on the rack implies
__________.
A. Defects
B. Unnecessary Motion
C. Inappropriate Processing
D. Complexity

Wrong! You answered: D

Frontline people are not usually the best individuals to go to for solutions to a
company's problems with waste.
F

Wrong! You answered: T

A good question to ask new hires is, "How do you feel we can better
ourselves as a company?"
T

Correct!

A good motto to have is, "Keep it simple".

T

Correct!

Discourage the sharing of ideas by those not in management; they are there
to work.

Correct!

It is a given that the more money you spend for a solution to a problem the
better value you will get.
F

Correct!

Challenge Question: How can the waste of defects be coupled with the waste
of Human Resources?

Defects are the result of __________.

A. poor planning before one gets started
B. things not being done right the first time
C. something wrong in the process
D. all of the above

Correct!

Defects result in __________.

A. the product not working
B. the employee not working
C. the service not working
D. "a" and "c" are correct

Correct!

We may have more than one root cause to a defect so it is important to

__________.
A. keep measuring to see if a defect is truly gone
B. eliminate the process experiencing the defect
C. look for a different product to produce
D. all of the above

Correct!

A defect is best described as the __________ of a problem in our process.

A. beginning
B. root cause
C. symptom
D. all of the above

Wrong! You answered: B

An effective way to root cause a problem is a tool called __________.

A. 5 why analysis
B. Get to the root.
C. Root it out.
D. Why is it so

Correct!

It is important to find out which person is responsible for the cause of a

defect and hold them accountable for their error.
F

Correct!

When you have frequent errors in paperwork our service doesn't work and
the customer is not pleased
T

Correct!

Root causing defects is an important practice for any company.

T

Correct!

Asking "Why?" over and over again is an effective way to get to the root of a
problem.
T

Correct!

A good motto in Lean is, "If at first you don't succeed, try and try again."
F

Correct!

Challenge Question: Any defect in products or services is wasteful. Discuss

the wastes in dealing with defects.
PHYSICAL AND CHEMICAL DEFECTS.

The 2nd principle of Lean Thinking is to:

A. zero in on the wastes
B. brainstorm for improvements
C. draw a floor plan
D. identify the value stream

Correct!

In a value stream map

A. we start by drawing the process closest to the customer
B. we use a paper and pencil to draw with
C. we choose a product/service to focus on before we begin to draw
D. All of the above

Correct!

The action plan is a list of activities to be used in order to:

A. achieve the future state
B. move upstream through a process
C. utilize a standard language
D. draw an accurate map

Wrong! You answered: D

The future state map answers the question "What would the process look
like?"
A. if we work our way downstream
B. if we were to run it in reverse
C. if we were able to eliminate the NVA activities
D. none of the above

Correct!

A value stream is all of the NVA activities that deliver a product/service to the
customer.
F

Correct!

In a value stream map we draw the material transformation process first.

T

Correct!

A value stream map can only be read by certain departments in an

organization.
F

Correct!

Once we have established what the challenges to a process are we

brainstorm for improvements.
T

Correct!

Value stream mapping allows organizations to communicate utilizing a

standard language.
T

Correct!

Challenge Question: Give a brief step by Step breakdown, describing the

creation of a Value Stream Map.
In the value stream mapping material should flow from supplier to the
company and from company to the customer.The information should flow
from customer to the company and from company to the supplier