Lean Bronze Certification Exam Study Guide with
Complete Solutions
Continuous Flow - Correct Answer high production volume, highly standardized commodity products
Jidoka - Correct Answer automatically stopping the process when something is wrong and then fixing
the problems on the line itself as they occur
Autonomous Maintenance - Correct Answer An improvement process focused on improving the
condition of a machine and then identifying, standardizing and training on operator maintenance
tasks
Andon light - Correct Answer Signal for a need or problem with equipment or process. Example of
visual management
A3 document - Correct Answer This helps to capture and share knowledge in a structured way. Its
commonly used as a problem-solving tool. This should also be used as a coaching tool between a
coach and a learner. Reference Managing to Learn by John Shook.
Empowered Employees - Correct Answer The heart and soul of a lean organization according to
Masaaki Imai (Gemba Kaizen)
Sort - Correct Answer The first step of 5S
Highland Park - Correct Answer The Ford Factory that housed the Model T production
consensus - Correct Answer A general agreement by team members. Not everyone may fully agree
with the idea but no one is openly opposed and they can "live with it".
Goal of Hoshin Kanri - Correct Answer To align the tactical actions and improvements to the strategic
objectives of the business. This is a layered process which should be flowed from the higher level
group and then down to the next level.
cross-functional team - Correct Answer Employees from different areas coming together to complete
a task or solve a problem
, Sequential pull system - Correct Answer A type of system is used when product variation is high and
it doesn't make sense to keep an inventory of each product. With this type of system, we control the
overall inventory in the system by only releasing when a trigger is created.
interchangeable parts - Correct Answer According to Dennis (Lean Production Simplified), the
greatest enabler of mass production
Standardized Work & Jidoka - Correct Answer "Separating Man from Machine" describes the ability
to have one operator run multiple machines. This is enabled by
Standardized Work - Correct Answer Route of the operator is clear and documented
Little's law - Correct Answer The relationship between work in process (WIP), throughput and lead
time
PQCDSM - Correct Answer A core set of goals and measures that we are tracking on a daily basis.
Value Stream - Correct Answer The entire sequence of work required to bring a product from raw
material to delivery
Theory of Constraints - Correct Answer "The Goal" by Goldratt popularized this concept which
focuses on bottleneck management
Joseph Juran - Correct Answer This person introduced the Pareto principle as it applies to quality
control
PERT Calculations - Correct Answer (Optimistic + 4 x Most Likely + Pessimistic) / 6
PERT - Correct Answer A scheduling and program planning method
SMART goal - Correct Answer Specific, Measurable, Achievable, Realistic and Timely
Complete Solutions
Continuous Flow - Correct Answer high production volume, highly standardized commodity products
Jidoka - Correct Answer automatically stopping the process when something is wrong and then fixing
the problems on the line itself as they occur
Autonomous Maintenance - Correct Answer An improvement process focused on improving the
condition of a machine and then identifying, standardizing and training on operator maintenance
tasks
Andon light - Correct Answer Signal for a need or problem with equipment or process. Example of
visual management
A3 document - Correct Answer This helps to capture and share knowledge in a structured way. Its
commonly used as a problem-solving tool. This should also be used as a coaching tool between a
coach and a learner. Reference Managing to Learn by John Shook.
Empowered Employees - Correct Answer The heart and soul of a lean organization according to
Masaaki Imai (Gemba Kaizen)
Sort - Correct Answer The first step of 5S
Highland Park - Correct Answer The Ford Factory that housed the Model T production
consensus - Correct Answer A general agreement by team members. Not everyone may fully agree
with the idea but no one is openly opposed and they can "live with it".
Goal of Hoshin Kanri - Correct Answer To align the tactical actions and improvements to the strategic
objectives of the business. This is a layered process which should be flowed from the higher level
group and then down to the next level.
cross-functional team - Correct Answer Employees from different areas coming together to complete
a task or solve a problem
, Sequential pull system - Correct Answer A type of system is used when product variation is high and
it doesn't make sense to keep an inventory of each product. With this type of system, we control the
overall inventory in the system by only releasing when a trigger is created.
interchangeable parts - Correct Answer According to Dennis (Lean Production Simplified), the
greatest enabler of mass production
Standardized Work & Jidoka - Correct Answer "Separating Man from Machine" describes the ability
to have one operator run multiple machines. This is enabled by
Standardized Work - Correct Answer Route of the operator is clear and documented
Little's law - Correct Answer The relationship between work in process (WIP), throughput and lead
time
PQCDSM - Correct Answer A core set of goals and measures that we are tracking on a daily basis.
Value Stream - Correct Answer The entire sequence of work required to bring a product from raw
material to delivery
Theory of Constraints - Correct Answer "The Goal" by Goldratt popularized this concept which
focuses on bottleneck management
Joseph Juran - Correct Answer This person introduced the Pareto principle as it applies to quality
control
PERT Calculations - Correct Answer (Optimistic + 4 x Most Likely + Pessimistic) / 6
PERT - Correct Answer A scheduling and program planning method
SMART goal - Correct Answer Specific, Measurable, Achievable, Realistic and Timely
