ANSWER: B

One of Van's best clients, Daniel, is interested in ordering 100 pairs of tennis shoes...but only if
he can pick them up this Friday. How do you figure out if you can meet customer demand?

A. Schedule a Kaizen Event.

B. Calculate Takt Time.
C. Create a Value Stream Map.
D. Tell Daniel whatever he wants to hear. You're off on Friday.
ANSWER: A
TPM (Total Productive Maintenance) targets which of the following?

A. Zero losses
B. Zero lunch breaks
C. Zero operator intervention
D. Zero excess inventory
ANSWER: A
You have a great relationship with your local fitting supplier - they consistently provide you with
high quality parts.

In a Lean shop, incoming inspection of these parts is:

A) A non-value added process

B) Vital to ensure product quality
C) Required to reduce scrap
D) Required to reduce work
ANSWER: A
Kanban is a visual system for controlling production.

A) True
B) False
ANSWER: A
One-piece flow would have the most significant impact on which type of inventory?

A) Work in process
B) Finished Goods
C) Kaizen supplies
D) None of the above
ANSWER: A
Developing standard work can be an aspect of a Kaizen event.

A) True
B) False
ANSWER: A
Implementing Lean often results in improved energy efficiency

A) True
B) False
ANSWER: B
A good lean program can eliminate the need for Total Productive Maintenance (TPM).

A) True
B) False
ANSWER: B
In lean manufacturing, "waste" is anything that adds value.

A) True
B) False
ANSWER: B
A manufacturing process that waits for a customer order would be referred to as a ____ ?

A. Push system
B. Pull system
C. Visual Cue system
D. First In First Out (FIFO) system
ANSWER: B
The primary objective of SMED (Single Minute Exchange of Die) is to:

A. Organize and clean the workplace in one minute intervals

B. Reduce the time required to complete the changeover of production
C. Keep equipment maintained
D. None of the above
ANSWER: A
Implementing Lean often results in improved energy efficency.

A. True
B. False
ANSWER: A
A value stream map shows the relationship between the information flow and the material
flow.

A. True
B. False
ANSWER: D
"Kaizen" is best applied to the:

A. Manufacturing process
B. Administrative process
C. Supplier process
D. All of the above
ANSWER: D
What is Kaizen?

A. A defect analysis methodology

B. A tool to calculate customer value
C. A Ninja Warrior
D. A focus on making small but consistent improvements
ANSWER: A
"Elimination of waste" is one of the primary focuses of Lean.

A. True
B. False
ANSWER: A
An Andon can signal a shortage of material.

A. True
B. False
ANSWER: D
In a lean shop, products with low demand are typically _____.

A. Sourced from another supplier instead of built in-house

B. Batch processed and held in stock until a customer requests shipment
C. Scrapped
D. Produced in the quantity needed.
ANSWER: B
Sometimes the production process involves steps that are necessary, but don't actually add any
value.

If NVA is the acronym for Non-Value Added, what does NVAR mean?

A. Non-Value Added Rating

B. Non-Value Added Required
C. Non-Variable Add Recaito
D. Non-Value Added Returned
ANSWER: B
What rule of lean focuses on eliminating variation from a process?

A. Flow
B. Standard Work
C. Takt Time
D. Pull
ANSWER: B
You are taking part in a Kaizen event focused on finding and removing waste within a
production process.

Which of the following production steps should be eliminated as soon as they are identified?

A. Value Added (VA)

B. Non-Value Added (NVA)
C. Non-Value Added-Required (NVAR)
D. All of the above
ANSWER: A
Elimination of waste is one of the primary focuses of Lean.

A. True
B. False
ANSWER: C
The primary objective of lean manufacturing is to _____.

A. Keep labor costs as low as possible by utilizing excess inventory

B. Produce products with fewer options, simplifying consumer choices
C. Maximize the value of the product to the customer while minimizing waste
D. Outsource the manufacturing of basic components to focus only on final assembly
ANSWER: A
A value stream map shows the relationship between the information flow and the material
flow.

A. True
B. False
ANSWER:C
In Lean Manufacturing, "cycle time" means _____.

A) The amount of time a machine needs to run a specific operation

B) Employees must use company bicycles for all local part deliveries
C) The time that elapses between customer order and customer payment
D) Running larger lot sizes
ANSWER:C
"One-piece-flow" means ______.

A) Batching
B) Larger lot sizes become necessary
C) One piece moves from one operation to the next
D) Machine operators must work harder but produce less
ANSWER:A
A production line that never stops can be either really good for business or a really bad idea; it
all depends on production demand.
A) True
B) FaLse
ANSWER:C
A manufacturing "cell" is:

A. An amoeba that makes things

B. A unit of measure
C. A layout that moves sequential operations close together
D. A management tool designed to decrease morale
ANSWER:C
In what industry did "Lean Manufacturing" first develop?

A. The food industry

B. The fitness industry
C. The automotive industry
D. The City of Industry, California
ANSWER:C
To a "lean" thinker, which of the following would NOT be considered waste?

A. Overproduction
B. Waiting
C. Excess Machine Capacity
D. Transport of Materials
ANSWER: A
Implementing Lean often results in improved energy efficiency.

A. True
B. False
ANSWER: A
"One piece flow" production can, in some cases, eliminate the need for "work-in-process"
inventory.

A. True
B. False
ANSWEr: B
What are two goals of Lean Manufacturing?

A) Eliminate jobs & increase available inventory

B) Eliminate waste & maximize value to the customer
C) Eliminate excess storage space & increase lead times
D) None of the above
ANSWER: C
To successfully implement Lean Manufacturing, manufacturers should ____.

A) Keep as much available inventory on-hand as possible.

B) Reduce employee headcount by at least 20%.
C) Continuously strive to reduce all forms of waste, including wasted time.
D) None of the above
ANSWER: B
Implementing Lean manufacturing requires a huge financial investment.

A) True
B) False
ANSWER: B
Lean manufacturing only works in high-production environments.

A) True
B) False