Lean Bronze Exam Questions and
Answers with Verified Solutions | 2025
2.Given this data set, whats the first pass yield (FPY)?
Good pieces = 88
Scrap pieces = 10
Rework pieces = 2
Machine Uptime= 90% - ANSWER (100-12)/100=88
3. Which of the following is not a core element of the Toyota Production System? -
ANSWER Statistical Process Control
4. A tool used to implement a pull system is a ______ - ANSWER Kanban
5. The first step in value stream mapping is always to: - ANSWER Identify the
customer and define value
6. Batch Processing often creates the following: - ANSWER . Longer Intervals
Quality Issues
Longer Leadtimes
* All of the above
7. Another common name for the Cause and Effect (Fishbone) Diagram is the: -
ANSWER Ishikawa Diagram
,8. The book that was widely credited with popularizing lean manufacturing across
North America in the 1990s was called: - ANSWER The Machine That Changed
the World
9. Henry Ford's ideas were revolutionary for the manufacturing world but Fordism
wasn't without its faults. Which of the following are reasons why Ford's
production methods were not sustainable? - ANSWER Ford viewed his
employees as a variable expense
Quality was the job of engineers
Ford's production lines were not flexible
All of the above
10. Which of the following wastes is typically viewed as the worst form of waste? -
ANSWER Overproduction
11. Which of the following statements are true regarding an A3? - ANSWER . It
is a problem solving tool that can be used by any employee in the company
Its a coaching tool between a learner and a teacher
It is a document A3 size that helps capture and share knowledge in a structured
way
All of the above
12. What event sparked the creation of the Toyota Production System? -
ANSWER A visit by a japanese engineer to a Ford Factory
, 13. Understanding value is an important part of lean manuafacturing. Indicate
which of the following activities are value added: - ANSWER Transform the raw
material
14. According to Pascal Dennis (Lean Production Simplified), which factor has the
greatest impact on safety? - ANSWER Poor Ergonomics
15. Given that my leadtime is 8 minutes, I make 2 cars per minute and the average
value of a car in the assembly process is $10,000, what is my inventory value
approximately? - ANSWER 10000*2=20,000*8=160,000
16. What is the foundation of Toyota's House of Lean Production? - ANSWER
stability
17. Development of people is a core part of a lean culture. What is a key
difference between mentoring and coaching? - ANSWER Mentoring should be
done one on one while coaching doesn't have to be
18. What is the purpose of red tagging as it relates to 5S? - ANSWER Identify
material, tools or equipment that you want to remove from a work area
19. Which of the following is not one of the 5 lean principles captured by Jones
and Womack in "The Machine that Changed the World"? - ANSWER Ensure a
clean and safe working environment
20. What is the capacity of a produciton cell given that:
Total time per shift = 480 minutes
Answers with Verified Solutions | 2025
2.Given this data set, whats the first pass yield (FPY)?
Good pieces = 88
Scrap pieces = 10
Rework pieces = 2
Machine Uptime= 90% - ANSWER (100-12)/100=88
3. Which of the following is not a core element of the Toyota Production System? -
ANSWER Statistical Process Control
4. A tool used to implement a pull system is a ______ - ANSWER Kanban
5. The first step in value stream mapping is always to: - ANSWER Identify the
customer and define value
6. Batch Processing often creates the following: - ANSWER . Longer Intervals
Quality Issues
Longer Leadtimes
* All of the above
7. Another common name for the Cause and Effect (Fishbone) Diagram is the: -
ANSWER Ishikawa Diagram
,8. The book that was widely credited with popularizing lean manufacturing across
North America in the 1990s was called: - ANSWER The Machine That Changed
the World
9. Henry Ford's ideas were revolutionary for the manufacturing world but Fordism
wasn't without its faults. Which of the following are reasons why Ford's
production methods were not sustainable? - ANSWER Ford viewed his
employees as a variable expense
Quality was the job of engineers
Ford's production lines were not flexible
All of the above
10. Which of the following wastes is typically viewed as the worst form of waste? -
ANSWER Overproduction
11. Which of the following statements are true regarding an A3? - ANSWER . It
is a problem solving tool that can be used by any employee in the company
Its a coaching tool between a learner and a teacher
It is a document A3 size that helps capture and share knowledge in a structured
way
All of the above
12. What event sparked the creation of the Toyota Production System? -
ANSWER A visit by a japanese engineer to a Ford Factory
, 13. Understanding value is an important part of lean manuafacturing. Indicate
which of the following activities are value added: - ANSWER Transform the raw
material
14. According to Pascal Dennis (Lean Production Simplified), which factor has the
greatest impact on safety? - ANSWER Poor Ergonomics
15. Given that my leadtime is 8 minutes, I make 2 cars per minute and the average
value of a car in the assembly process is $10,000, what is my inventory value
approximately? - ANSWER 10000*2=20,000*8=160,000
16. What is the foundation of Toyota's House of Lean Production? - ANSWER
stability
17. Development of people is a core part of a lean culture. What is a key
difference between mentoring and coaching? - ANSWER Mentoring should be
done one on one while coaching doesn't have to be
18. What is the purpose of red tagging as it relates to 5S? - ANSWER Identify
material, tools or equipment that you want to remove from a work area
19. Which of the following is not one of the 5 lean principles captured by Jones
and Womack in "The Machine that Changed the World"? - ANSWER Ensure a
clean and safe working environment
20. What is the capacity of a produciton cell given that:
Total time per shift = 480 minutes
