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F-ACAD-22B

SUBJECT: LEAN MANUFACTURING


Instructions to students
1) Enter your name, student number and section at the top of the answer sheet
2) This test paper contains 70 multiple choice questions, each carrying equal marks.
3) Candidates must answer all the questions on this paper.
4) Select the ONE letter corresponding to the MOST APPROPRIATE answer for each
question, and place an X in the appropriate box on the answer grid.
5) Stop immediately when time is up.
6) You may not leave the room before the allocated time is up or as approved by the
facilitator
7) The answer sheet must be handed in at the end of the test. You may get the question
sheet.

[EXAMPLE]
1. Name the person accredited for perfecting interchangeable parts.
a. Eli Whitney
b. Taiichi Ohno
c. Henry Ford
d. Lillian Gilbreth
In this example, the correct answer is A) Eli Whitney and should be indicated as:
A
Question 1

Mark

If you wish to change your answer, the original answer must be clearly crossed out so that
the desired answer is absolutely clear. If there is any doubt as to your desired answer, that
response will receive no marks.

Success seems to be connected with action. Successful people keep moving.


They make mistakes, but they dont quit.
- Conrad Hilton

F-ACAD-22B

NAME: _______________________________________
STUDENTs NUMBER: ___________________________
A

SECTION: ___________

Mark

Question 1

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SCORE

SCORE
A

Question 41

Mark
Question 61

Mark

Mark

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Question 42

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SCORE

SCORE

TOTAL SCORE:
1. He conducted research on income distribution and found out that 80% of wealth was
held by only 20% of the population. He then, developed his findings into a universal law:
80% of anything is attributed to 20% of its causes.
a. Vilfredo Pareto
b. Wilfredo Pareto
c. Kaoru Ishikawa
d. Shingeo Shingo

F-ACAD-22B

2. Typically, ____% of all lead time is non-value-added


e. 25%
f. 50%
g. 75%
h. 95%
3. Which of the following is not a benefit of Lean Manufacturing?
a. Productivity Increase
b. WIP inventory Reduction
c. Throughput Increase
d. Throughout time increase
4. Which of the following activities add value?
a. Deburring a surface after machining
b. Moving from one operation to another operation
c. Cleaning parts before processing
d. None of the above
5. The complete elimination of all waste, so that all activities along a value stream add
value to the product
a. Perfection
b. Continuous Improvement
c. Lean Manufacturing
d. Current State Map
6. This refers to all of the activities and information streams that exist between the raw
material supplier and the possession of the customer
a. Value
b. Value Stream
c. Value Stream Map
d. Lean Manufacturing
7. It is a process for changing over equipment from one part or product to another in as
little time as possible
a. A3
b. SMED
c. Gemba Walk
d. OEE
8. Within Non-Value-Added Work is __________ and _____________
a. Value-Added Work, Non- Value Added Work
b. Identification, Elimination
c. Mura, Muri
d. Required Waste, Pure Waste
9. Which of the following is not minimum information needed on a card that signals the
pull system?
a. Part number

F-ACAD-22B

b. Quantity/Inventory
c. Part Description
d. Part Drawing
10. This refers to the identification and elimination of wastes inside the Value Stream
a. Kaizen
b. Quick Changeover
c. Lean Manufacturing
d. Agile Manufacturing
11. It
a.
b.
c.
d.

is the variation in the operation of a process not caused by the end customer.
Mura
Muri
Muda
Mudi

12. This refers to those activities that must be done for legal purposes. Company pays you
to do it, but its still waste
a. Required Waste
b. Values
c. Pure Waste
d. Value Added Work
13. Activities that take time or resources but do not satisfy customer requirements
a. Non-Value added Work
b. Value Added Work
c. Pure Waste
d. Downtime
14. Activities that the customer is willing to pay for
a. Value
b. Idle Time
c. Non-Value added Work
d. Value Added Work
15. Waste related to the inspection or repair of a product or service to fulfill customer
requirements
a. Inventory
b. Mura
c. Defects
d. Inspection Error
16. Which of the following andon does?
a. Detect defects
b. Prevent defects from being passed forward
c. Solve anomalies
d. Replace good verbal communication between workers or teams
17. Marking Standard which means object must always be in the area
a. Closed Box
b. Open Box
c. Marked Edges

F-ACAD-22B

d. Unmarked Edges
18. Within every operation is ________________ and ______________ Work
a. Value-Added Work, Non- Value Added Work
b. Identification, Elimination
c. Mura, Muri
d. Required Waste, Pure Waste
19. Which of the following will reduce or eliminate the waste of overproduction?
a. Build what the customer needs, when it is needed, in the quantity needed.
b. Shift from machine focus to people focus.
c. The focus must be on the operator and the machine, as opposed to the material.
d. Bring an open mind to work and always think about how to improve the process
20. Multiple bosses creating multiple jobs for people and sending emails/memos to
everyone are examples of which kind of wastes?
a. Inventory
b. Overproduction
c. Non-utilizing employees KSA
d. Waiting
21. Which of the following will reduce or eliminate the waste of waiting?
a. Build what the customer needs, when it is needed, in the quantity needed.
b. Shift from machine focus to people focus.
c. Bring an open mind to work and always think about how to improve the process
d. The focus must be on the operator and the machine, as opposed to the material.
22. Which of the following will reduce or eliminate the waste of motion?
a. Build what the customer needs, when it is needed, in the quantity needed.
b. Shift from machine focus to people focus.
c. Bring an open mind to work and always think about how to improve the process
d. The focus must be on the operator and the machine, as opposed to the material.
23. This refers to those costs without benefits
a. Idle Times
b. Wastes
c. Values
d. Profits
24. What is this waste that refers to the effort of adding no value to the product or service
from the customers viewpoint?
a. Inventory
b. Non-value added work
c. Excess Processing
d. Waiting
25. It
a.
b.
c.

is a measure of how spread out numbers are. Its symbol is (the Greek letter sigma)
Standard Deviation
Mean
Variance

F-ACAD-22B

d. Cumulative Variance
26. It is an agreed-upon set of work procedures that establish the best and most reliable
methods and sequences for each process and each worker.
a. Standard
b. Mean
c. Variance
d. Cumulative Variance
27. He was an Industrial Engineer credited with developing a quick changeover
methodology
a. Henry Ford
b. Sinichi Toyoda
c. Shingeo Shingo
d. Shingeo Toyoda
28. A picture composed of lines and words designed to represent a meaningful relationship
between an effect and its causes. It groups causes according to selected categories
a. Ishikawa Diagram
b. Pareto Diagram
c. Check Sheet
d. A3
29. Positive correlation:
a. as x increases, y increases
b. as x increases, y decreases
c. No evidence that y is directly affected by a changes in x
d. as x increases, x increases
30. The use of controls that will enable an individual to immediately recognize the
standard and any deviation from it
a. Pokayoke
b. Control Charts
c. Visual Business
d. Pareto Diagram

31. Which of the following is not a benefit of SMED?


a. Product and service diversity
b. Lower costs
c. Higher reliability and quality
d. Salary Increase
32. Which of the following is not a characteristic of Visual Business?
a. Exposes abnormalities
b. Allows for quick recovery
c. Enables work autonomy
d. Improves profit

F-ACAD-22B

33. Stopping a process immediately to fix errors


a. Jidoka
b. Pokayoke
c. A3
d. VSM
34. What are the steps in Jidoka?
a. Investigate, Detect, Stop, Fix, , Standardization
b. Fix, Detect, Stop, , Investigate, Standardization
c. Detect, Stop, Fix, Investigate, Standardization
d. Detect, , Fix, Stop, Investigate, Standardization
35. In
a.
b.
c.
d.

a lean environment, this refers to a status-display station


Andon
Pokayoke
Jidoka
Detect

36. A
a.
b.
c.
d.

predetermined communication plan with pre-defined ifthen statements


Contengency Planning
Andon
Pokayoke
Escalation Planning

37. Father of the Toyota Production System


a. Henry Ford
b. Sinichi Toyoda
c. Shingeo Shingo
d. Eiji Toyota
38. Why do you think we recommend videotaping the process?
a. in order to capture all of the activities and to document the current state,
b. provide a means to analyze the process
c. provide objective time related data
d. all of the above
39. Total time from last good piece with old tools to first good piece(s) with new tools, at
expected process performance parameters
a. Lead Time
b. Setup Time
c. Carrying Time
d. Holding Time
40. Can you think of any activities that can be performed before or after the set-up
process is done, and while the process is actually running?
a. Retrieving the tooling, materials and information ahead of time
b. Returning the tooling or materials from the prior job after the set-up process has
been completed and the process is up and running
c. Preparing materials (e.g. pre-heating) prior to the set-up process
d. All of the above

F-ACAD-22B

41. It
a.
b.
c.
d.

is the production of large amounts of standardized products on production line.


Lean production
Craft production
Agile production
Mass production

42. Products were produced one at a time and were generally unique
a. Lean production
b. Craft production
c. Agile production
d. Mass production
43. Which of the following is a major issue of mass production?
a. Increased product handling
b. Additional transportation and storage
c. Rework of Products
d. All of the above
44. To monitor effect of implementation of project plan & find Countermeasures to further
improve the solution.
a. Plan
b. Do
c. Check
d. Act
45. To Enlighten the Team as to the Real Problem by analyzing the Data and defining and
implementing a solution plan
a. Plan
b. Do
c. Check
d. Act
46. To investigate the current situation & understand fully the nature of the problem being
solved.
a. Plan
b. Do
c. Check
d. Act
47. To
a.
b.
c.
d.

Review Continuously the Performance Measure & make adjustments as required.


Plan
Do
Check
Act

48. It is a process of reducing variation from the production schedule


a. Mura

F-ACAD-22B

b. A3
c. Gemba
d. Heijunka
49. It
a.
b.
c.
d.

is the Waste, work that does not add any value to the product
Mura
Muri
Muda
Mudi

50. Customers orders vary from month to month, creating uneven production scheduling.
Build-to-order companies will be building huge quantities, paying overtime, and stressing
their people and equipment one week, but then sending them home the next due to light
orders. How do we call this kind of build-to-order approach?
a. hurry up, then slow down
b. Mass production
c. Customized production
d. Overtime
51. What are the benefits of leveling production schedule?
a. Reduced risk of unsold goods
b. Balanced use of labor and machines
c. Smoothed demand on the upstream processes and suppliers
d. All of the above
52. What are the three components of leveling?
a. Volume, Variety and Time
b. Volume, Customer Demand and Time
c. Variety, Customer Demand and Time
d. Customer Demand, Time, Labor

53. It
a.
b.
c.
d.

is the overburden on equipment, facilities & people


Mura
Muri
Muda
Mudi

54. Which of the following is not a common cause of project failure?


a. People tend to jump to solutions
b. During the project, solution is not challenged anymore
c. Unanticipated events occur during the life cycle of projects
d. Focused group
55. A
a.
b.
c.
d.

temporary activity undertaken to create a unique product, service or result


Labor Management
Project Management
Production Planning
Production Scheduling

F-ACAD-22B

56. What are the promises of Lean Project Management?


a. Improved customer satisfaction
b. Shorter through put times
c. Project Cost Savings
d. All of the above
57. This refers to the warroom where people has the ability to understand the status of a
project in 5 minutes or less by simple observation without use of computer or speaking to
anyone
a. Odeya room
b. Obeya room
c. Oleya room
d. Okeya room
58. This refers to the available time per customer demand
a. Cycle Time
b. Takt Time
c. Talk Time
d. Lead Time
59. It is a signaling device that gives authorization and instructions for the production or
withdrawal (conveyance) of items in a pull system.
a. Kanban
b. Heijunka
c. Andon
d. Gemba

60. The purpose of the ____ is to tell the story of an opportunity and how it was addressed,
using one sheet of paper.
a. A3
b. A4
c. A5
d. A6
61. The reason we call A3 as _____________ is because you are trying to tell a story through
the document. When you interact with team members and stakeholders, you are sharing
and testing your ideas. Like a story, it will evolve.
a. Dialogue
b. Storyboard
c. Conversation
d. Lean tool
63. Its fundamental objective is to create value in the most effective and efficient way
a. Lean Manufacturing
b. Lean Production
c. Lean Thinking

F-ACAD-22B

d. System Thinking
64. The set of shared attitudes, values, goals and practices that characterizes an
institution, organization, or group
a. A3 Culture
b. Culture
c. Lean Culture
d. System Thinking
65. In
a.
b.
c.
d.

business, _______ is the place where value is created; where the work is done
Lemba
Gemba
Memba
Kambe

66. Agreement by the group on countermeasures that address the reasonable concerns of
all stakeholders
a. Stakeholders
b. Consensus
c. Gemba
d. Countermeasure
67. __________ are temporary responses to specific problems that will serve until a better
approach is found or until conditions change
a. Fix
b. Solution
c. Countermeasures
d. Action Plan
68. The purpose of this tab is to provide a place to document the improvement to relevant
metrics that occurred during the identified project.
a. Boxplot
b. Box score
c. Box Tab
d. Box chart
69. Complete the quote: A problem well stated is a _______________
a. Solution to be solved
b. Problem completely solved
c. Problem Half solved
d. DMAIC
70. Which of the following is most correct way to state a problem in a A3?
a. The printer closest to Department ABC is down two flights of stairs from employee A
b. Last month there was a 25% decline in throughput on Product Line
c. Airplanes are hard to control. The airplanes are assumed to show low performance,
therefore, root cause must be known to solve the issue. Airplanes may not be safe
to be used in the airline; therefore, it must be improved.
d. In the last 3 months, 7% of vendors complained that we paid our bills 10 or more
days late

F-ACAD-22B

THANK YOU SO MUCH