Lean Bronze Certification Questions and Answers

Lean Bronze Certification Questions and Answers C. Pull System The concept of the downstream process going to the upstream process to pick up product is called: a. Just in time b. Push system c. Pull system d. visual factory a. Increase the capacity of the constraining workstation A multi-step manufacturing process' capacity is limited by one if its workstations. To increase the process' capacity, the factory must: a. Increase the capacity of the constraining workstation b. Increase production starts (work put into the first operation) c. Decrease the utilization of all workstations in the process d. Decrease the utilization of the constraining workstation b. Line Balancing The optimal number of workers may be determined by: a. Standard cost data b. Line balancing c. Labor and Overhead d. Industry standard d. Production workers Production standards in a lean system should be established by: a. Scheduling managers b. process engineers c. efficiency experts d. Production workers b. root cause of the problem The greatest contribution of the 5- why analytical tool is that it helps the lean practitioner to identify the: a. solution to the problem b. root cause of the problem c. number of occurrences of the problem d. person who caused the problem b. create a current state value stream map To identify waste in a selected production line, the first step is to: a. Perform 5-S activities to organize the line b. create a current state value stream map c. determines the specific material that runs in the line d. perform a time and motion study c. Changing the shape or character of a product or assembly Which of the following is considered value-added work? a. Eliminating all defects and the need for rework b. Empowering employees to establish their own work standards c. Changing the shape or character of a product or assembly d. activities that must be performed under present work conditions c. the complete elimination of waste The basis of the Toyota Production System is: a. the monitoring of time vs. order and delivery b. Five S, 5 Why's and the 7 wastes c. the complete elimination of waste d. standardized work and visual factory c. Waste The ultimate goal of lean is the total elimination of: a. downtime b. overtime c. Waste d. Errors c. Overproduction (Mother of all wastes) The worst waste of all, because it opens the door for other kinds of waste is: a. Transport b. Overprocessing c. Overproduction d. motion c. Assist you in identifying and eliminating all forms of waste A Value Stream Map is a tool to: a. Help you identify which workers are poor performers b. Enable managers to better understand their backlog c. Assist you in identifying and eliminating all forms of waste d. Assist managers to better understand their on-time delivery d. Identify material for potential removal In a 5S program, the purpose of red tagging is to: a. provide visual management of WIP b. Identify broken equipment for repair c. Highlight processes for continuous improvement d. Identify material for potential removal c. 105 minutes (Pitch formula; Pitch = takt time x pack out qty) (3x 35= 105) In a process with a Takt time of 3 minutes and a pack out qty of 35 parts, the Pitch is: a. 35 minutes b. 90 minutes c. 105 minutes d. 11.66 minutes c. one unit every 50 seconds Takt time = available working time (AWT) / customer demand (CD) AWT = 28,800 Seconds (8 hrs) - 1800 seconds (breaks)= 27,000 CD= 2700 Units / 5 days = 540 units per day Takt time = 27,000 seconds / 540 units = 50 seconds For a production facility working five days per week (one 8-hour shift with 3 Ten-minute breaks), the customer demand is 2700 units per week. What is the Takt time this facility should produce to? a. one unit every 54 seconds b. one unit every 10 seconds c. one unit every 50 seconds d. one unit every 57 seconds b. 2 minutes Takt= daily operating time / required quantity per day, so Takt= ((8 hours x 60 mins/hrs)- 20 mins)/230, so Takt time= 460 / 230, so Takt= 2 minutes The Takt time for a single 8- hour shift operation (less than 20 mins for employee breaks per shift) with a daily demand of 230 units per shift is: a. 2.09 minutes b. 2 minutes c. 4 minutes d. 1/2 minute c. Withdrawal Kanban Kanban (Pull signal) that specifies the kind and quantity of product that the downstream process may pull out is known as: a. production Kanban b. downstream Kanban c. Withdrawal Kanban d. Customer Kanban d. Value Stream A______________ is all the actions (both value-added and non-value added) currently required to bring a product through the main flows essential to every product. a. Lean experience b. Customer demand c. Product Launch d. Value Stream c. Overproduction Which is considered to be the WORST of the seven wastes? a. Inventory b. motion c. Overproduction d. Defects c. Practice and Training A commonality between sports and work is the continuing need for: a. Skill and Maturity b. Strength and Endurance c. Practice and Training d. Emotion and Dedication a. 5% For most unimproved processes, the amount of value-added work relative to incidental work and waste is approximately: a. 5% b. 50% c. 25% d. 80% d. Safety Stock The amount of stock kept on hand to compensate for variation in supplier lead time and upstream processes is known as: a. Lead time stock b. Cycle time stock c. Strategic stock d. Safety Stock c. Takt time is the available work time divided by customer demand Which of the following is a true statement about takt time? a. Takt time is calculated after standardized work has been established b. Takt time is customer demand divided by available work time c. Takt time is the available work time divided by customer demand d. Takt time includes lunch and break times for an operator b. before continuous improvement can be made Standardizing and stabilizing the process are necessary steps: a. for reducing headcount b. before continuous improvement can be made c. to empower employee creativity d. before maximizing individual cell performance c. Team members In a lean factory, who is responsible for developing work standards? a. Industrial Engineer b. Process Engineer c. Team members d. Upper-level management a. select a product family What is the first step to cellularizing a production line? a. select a product family b. Identify potential bottle necks c. Perform process, quality-function-deployment (QFD) d. Identify and Label products and processes for group technology c. Continuous flow In its purest form, when items are processed and moved directly from one process to the next one piece at a time, it is known as: a. A "supermarket" pull system b. Value Stream Mapping c. Continuous flow d. Low volume Production b. A pull system (Kanban) The system used for managing and ensuring the flow of production materials in a just-in-time production system is known as: a. Load Leveling system (Heijunka) b. A pull system (Kanban) c. Manufacturing Resources planning (MRPII) d. Materials requirements planning (MRP) d. Just-in-time Kanban is a tool to support: a. 5S b. Six sigma c. Error proofing d. Just-in-time b. set production to match the rate of customer demand The purpose of Takt time is to: a. Obtain the fastest possible production speed b. set production to match the rate of customer demand c. coordinate with MRP scheduling d. ensures maximum machine efficiencies c. A product must be produced every "x" seconds to meet customer demand The takt time number means: a. Cycle assembly time must be greater than or equal to takt, never less b. the pace of manufacturing less downtime and scrap rate c. A product must be produced every "x" seconds to meet customer demand d. The time to make a product less lead time, available working time and line changeover c. changing the shape or character of a product or assembly Which of the following is considered value-added work? a. Activities that must be performed under present work conditions b. eliminating all defects and the need for rework c. changing the shape or character of a product or assembly d. Activities that must be performed under present work conditions c. Initiate continuous improvement in the value stream The purpose of the value stream performance analysis is to: a. motivate individual contributors to maximize their own output b. create competition for output between workcells c. Initiate continuous improvement in the value stream d. identify and blame poor performers in the value stream d. Hoshin planning (policy deployment) Measurements used to gauge problems, determine targets and then study the impact of improvement activities, check results and make appropriate adjustments are known as: a. lean metrics b. activity-based costing c. factory physics d. Hoshin planning (policy deployment) a. minimize machine downtime due to set-u Quick changeover is a lean principle used to: a. minimize machine downtime due to set-up b. allow for large batches and fewer changeovers c. standardize tooling d. reduce the number of set-ups c. Gemba The concept of management by walking around is most closely related to? a. Kaizen b. Pull Scheduling c. Gemba d. Recognition a. Empowered Employees The heart and soul of a lean organization according to Massaki Imai (Gemba Kaizen)? a. Empowered Employees b. A lean system c. Trained leadership d. Problem Solving a. A suggestion box on the wall Idea management systems are an important part of engaging employees at all levels. Which is NOT an element of a good suggestions system? a. A suggestion box on the wall b. A simple approval process c. A plan for recognition of ideas d. All ideas are encouraged even small ones c. Ask why 5 times to get to the root cause and then develop a plan to grow our people According to lean Production simplified, what should we do instead of blaming people for failures? a. Develop a fishbone diagram to find the root cause b. Retrain the person we are blaming c. Ask why 5 times to get to the root cause and then develop a plan to grow our people d. None of the above a. Leadership What is an enabler of a lean culture? a. Leadership b. 5S c. Steering committee d. Gemba d. All of the above Batch processing creates: a. Longer intervals b. Quality issues c. Longer lead times d. All of the above d. DMAIC The problem-solving process most commonly associated with six sigma a. PDCA b. 8D c. FMEA d. DMAIC b. negativity Which is not 7 + 1 wastes a. overproduction b. negativity c. defects d. waiting a. Andon During my operation in the production line I found a quality problem. I pull a cable to stop the line, and let the management know I need assistance. What is the tool I just used? a. Andon b. Jidoka c. Kaizen d. Poka Yoke c. Takt Time Which of the following might you find on standard work documents? a. Cost b. Supervisor's phone number c. Takt Time d. Scrap and Rework targets d. both A and B What should we expect from a SMED (Single minute exchange of dies) implementation? a. shorter lead times b. reduced inventories c. greater batch sizes d. both A and B a. Poke Yoke A physical device preventing an operator to install a component in the wrong orientation is an example of: a. Poke Yoke b. Andon c. SMED d. Fish bone a. Takt time, Work sequence, and in process stock What are the three elements of standard work according to lean production simplified: a. Takt time, Work sequence, and in process stock b. Takt time, cycle time and lead time c. Cycle time, inventory and wastes d. Work sequence, Production targets and inventory