Lean Manufacturing

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: C

"Kaizen" is best applied to the: A. Manufacturing process B. Administrative process C. Supplier process D. All of the above

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: 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: D

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

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: 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

Sometimes the production process involves steps that are necessary, but don't actually add any value. Therefore, if NVA is the acronym for "Non-Value Added" than what does NVAR mean? a. Non-Value Added Rating b. Non-Value Added Required c. Non-Variable Add Recaito d. Non-Value Added Refund

ANSWER: B

The focus of any Lean improvement process is the elimination of _____. a. Overtime b. Waste c. Flexibility d. Decision making ability

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: B

What are two Lean Manufacturing goals? a. Eliminate jobs & increase available inventory b. Eliminate waste & maximize value to the customer c. Eliminate excess storage space & shorten lead times d. None of the above

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: B

In a lean manufacturing facility, production is triggered by a. Company forecasts for long-term projected growth b. The production planner c. Product demand from the customer d. Balloons and confetti

ANSWER: C

"Elimination of waste" is one of the primary focuses of Lean. 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: A

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

ANSWER: A

Developing standard work can be an aspect of a Kaizen event. A) True B) False

ANSWER: A

Elimination of waste is one of the primary focuses of Lean. A. True B. False

ANSWER: A

Implementing Lean often results in improved energy efficency. A. True B. False

ANSWER: A

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

ANSWER: A

Kanban is a Japanese word for "signal." In Lean, the term "Kanban" is used in relation to purchasing, and refers to _____. a. A visual inventory hint (usually a card) that triggers an action b. A highway in Germany with no speed limit c. A quality control process d. None of the above

ANSWER: A

Kanban is a visual system for controlling production. A) True B) False

ANSWER: A

Lean methodology and techniques can be implemented across all departments within a manufacturing company - even departments like Accounting (payroll) or Inside Sales. Which statement best sums up the methodology of Lean Manufacturing? a. Small changes that add up to big improvements b. Manager driven workforce reduction c. Big improvements must be made and maintained by outside experts

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

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

What are The 5 S's? a. sort, straighten, shine, standardize, sustain b. sustain, surpass, select, shine, sort c. sort, shine, stand, sit, shuffle

ANSWER: A

When there are partially complete items in "WIP" that means you have _____. a. Work In Progress b. Work In Programming c. Wholesale Inventory Pricing d. What is Product

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

A good lean program can eliminate the need for Total Productive Maintenance (TPM). 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