Lean Bronze Final Exam |Questions with 100%
Correct Answers | Verified
Process Mapping - ✔️✔️1) The aim is to identify waste between and within processes.
2) These are detailed mapping, involving many steps, and focus on both the information and
material flows.
3) Some of the variables calculated are takt time and throughput yield
Little's Law - ✔️✔️Equates the flow time in terms of work-in-progress inventory in units and the
average completion rate computed in units per time period.
Example: staff can complete printing of about 100 books, while there are 500 books in various
stages of the printing department. Flowtime = 500/100 = 5 days. New orders will take 5 days to
complete
Throughput Rate - ✔️✔️Also known as flow rate. Calculates the rate at which the flow of units
passes from a particular process in the manufacturing unit. The maximum throughput rate is
the capacity of the process. It is calculated as the reciprocal of the cycle time.
Total Lead Time - ✔️✔️Lead time is the total time taken for the work to process from one point
to another in the process. It is calculated by calculating the total time one unit of product takes
to travel between all the processes. It includes the sum of the process lead times and the
waiting times in between different processes.
Process Cycle Efficiency - ✔️✔️Process cycle efficiency helps to detect how much of the process
is actually adding value to the entire process. It is calculated by using the following formula.
Process cycle efficiency = Value added time / Cycle time
Poka-yoke - ✔️✔️Mistake proofing.
, Pert Charts - ✔️✔️1) Clearly shows relationships between activities.
2) Easily understood by someone outside the project.
3) Deadlines and delegations can be specifically indicated next to each step.
4) Critical path may be easily identified and shown for planning and prioritization.
Gantt Charts - ✔️✔️1) Timeline at bottom shows relative length of project activities.
2) Empty bar lines can be filled in to indicate progress to date.
3) Unscheduled time readily identifiable if needed to be used.
4) Vertical line representing current date clearly shows potential problems.
Lean Thinking - ✔️✔️Five step thought process.
1) Specify value from the standpoint of the end customer by product family
2) Identify all the steps in the value stream for each product family, eliminating whenever
possible those steps that do not create value.
3) Make the value creating steps occur in tight sequence so the product will flow smoothly
toward the customer.
4) As flow is introduced, let customers pull value from the next upstream activity.
5) As value is specified, value streams are identified, wasted steps are removed, and flow and
pull are introduced, begin the process again and continue it until a state of perfection is
reached in which perfect value is created with no waste.
Value Added - ✔️✔️The following 3 must be met to be value added.
1) The customer must be willing to pay for it.
2) It changes the form, fit, or function of the product or service.
3) It must be done right the first time.
SIPOC - R - ✔️✔️Suppliers - Systems, people, organizations, or other soruces of the materials,
information, or other resources that are consumed or transformed in the process.
Correct Answers | Verified
Process Mapping - ✔️✔️1) The aim is to identify waste between and within processes.
2) These are detailed mapping, involving many steps, and focus on both the information and
material flows.
3) Some of the variables calculated are takt time and throughput yield
Little's Law - ✔️✔️Equates the flow time in terms of work-in-progress inventory in units and the
average completion rate computed in units per time period.
Example: staff can complete printing of about 100 books, while there are 500 books in various
stages of the printing department. Flowtime = 500/100 = 5 days. New orders will take 5 days to
complete
Throughput Rate - ✔️✔️Also known as flow rate. Calculates the rate at which the flow of units
passes from a particular process in the manufacturing unit. The maximum throughput rate is
the capacity of the process. It is calculated as the reciprocal of the cycle time.
Total Lead Time - ✔️✔️Lead time is the total time taken for the work to process from one point
to another in the process. It is calculated by calculating the total time one unit of product takes
to travel between all the processes. It includes the sum of the process lead times and the
waiting times in between different processes.
Process Cycle Efficiency - ✔️✔️Process cycle efficiency helps to detect how much of the process
is actually adding value to the entire process. It is calculated by using the following formula.
Process cycle efficiency = Value added time / Cycle time
Poka-yoke - ✔️✔️Mistake proofing.
, Pert Charts - ✔️✔️1) Clearly shows relationships between activities.
2) Easily understood by someone outside the project.
3) Deadlines and delegations can be specifically indicated next to each step.
4) Critical path may be easily identified and shown for planning and prioritization.
Gantt Charts - ✔️✔️1) Timeline at bottom shows relative length of project activities.
2) Empty bar lines can be filled in to indicate progress to date.
3) Unscheduled time readily identifiable if needed to be used.
4) Vertical line representing current date clearly shows potential problems.
Lean Thinking - ✔️✔️Five step thought process.
1) Specify value from the standpoint of the end customer by product family
2) Identify all the steps in the value stream for each product family, eliminating whenever
possible those steps that do not create value.
3) Make the value creating steps occur in tight sequence so the product will flow smoothly
toward the customer.
4) As flow is introduced, let customers pull value from the next upstream activity.
5) As value is specified, value streams are identified, wasted steps are removed, and flow and
pull are introduced, begin the process again and continue it until a state of perfection is
reached in which perfect value is created with no waste.
Value Added - ✔️✔️The following 3 must be met to be value added.
1) The customer must be willing to pay for it.
2) It changes the form, fit, or function of the product or service.
3) It must be done right the first time.
SIPOC - R - ✔️✔️Suppliers - Systems, people, organizations, or other soruces of the materials,
information, or other resources that are consumed or transformed in the process.
