Foundational Skills (Yellow Belt)

After data is collected on one or more of the six big losses, what Lean technique can be used to correct and/or eliminate the problem(s) A. Kaizen Event B. Changeover Reduction C. Error Proofing D. Visual controls

A. Kaizen Event

In the calculation for Overall Equipment Effectiveness (OEE) under which category is the time for unplanned breakdowns captured? A. Availability B. Performance C. Quality D. Overall

A. Availability

Which one of the following terms describes the product or service characteristics that are defined by the customer (internal or external) as important to their needs? A. Critical to Quality Variables B. Critical to Solution Variables C. Quality Management Directives D. Critical Operational Variables

A. Critical to Quality Variables

Which term can be used to measure the capability of a process? A. Defects per Million Opportunities (DPMO) B. Process Quality C. Just in Time (JIT) D. Design of Experiments (DOE)

A. Defects per Million Opportunities (DPMO)

Which Phase of Standard Work identifies the "best" approach to each work step, and standardizes that approach? A. Develop Standard Work B. Implement C. Establish Goals D. Analyze Current Process

A. Develop Standard Work

How is 5S/6S utilized during Lean improvement activities? A. Guides organizations to create and maintain an organized, clean and safe work environment as a foundation for achieving Lean B. Highlights the cost impact of adding queuing locations within the office area C. Used strictly in a manufacturing environment and is not generally utilized in any office or service Lean improvement activity D. Categorizes process steps into value-added and non value-added activities

A. Guides organizations to create and maintain an organized, clean and safe work environment as a foundation for achieving Lean

Which of the following is an example of Wasted Human Potential? A. Lack of proper tools, equipment, or supplies to properly perform the task B. An environment that builds morale C. Typographical errors D. Including everyone who performs a task in the improvement of that task

A. Lack of proper tools, equipment, or supplies to properly perform the task

A process map that provides an end-to-end view in only three to five steps is a... A. Level One process map. B. Level Two process map. C. Level Three process map. D. Level Four process map.

A. Level One process map.

DSub-optimization... A. Occurs when each individual function runs at peak performance without considering other functions or needs. B. Describes allowing sub-par performance of the supply chain. C. Considers not improving the entire process across the value stream to meet customer requirements

A. Occurs when each individual function runs at peak performance without considering other functions or needs.

Which of the following is an example of a self-explaining Visual Management technique? A. Pictures that describe the work that is taking place B. Written work procedures stored in a central library away from the work area C. Having root cause analysis reasons available D. Painting the floor with non-slippery material

A. Pictures that describe the work that is taking place

Which of the following best describes the type of maintenance that focuses on proactive maintenance to prevent breakdowns? A. Preventive Maintenance B. Corrective Maintenance C. Maintenance Prevention D. Breakdown Maintenance

A. Preventive Maintenance

The Red Tag event is part of which phase of 5S? A. Sort B. Set in Order C. Standardize D. Sustain E. Shine

A. Sort

Which Lean concept guides companies to document the best way to utilize their people, equipment, and materials in order to create a work method that meets the needs of the customer with the least amount of waste possible? A. Standard Work B. Kaizen Event C. 5S D. Eight Wastes

A. Standard Work

Which of the following is considered waste? A. Storing extra items in a warehouse B. Properly training operators C. Packaging products for shipment D. Handling customer orders

A. Storing extra items in a warehouse

What is the final phase of 5S? A. Sustain B. Shine C. Set in Order D. Standardize E. Sort

A. Sustain

In Workplace Design and Layout, standing is often better than sitting because it allows for ease of movement and is more flexible to the operator. A. True B. False

A. True

In a completed SIPOC Diagram, the requirement metrics have to be measurable. A. True B. False

A. True

Standard Work defines who, what, when and where work is to be performed. A. True B. False

A. True

The cellular environment and one-piece completion process of Continuous Flow enables organizations to identify and eliminate non value-adding activities that were previously hidden. A. True B. False

A. True

Total Productive Maintenance performance utilizes the Overall Equipment Effectiveness (OEE) metric to characterize the overall performance of a single piece of equipment or even an entire factory. A. True B. False

A. True

In Workplace Design and Layout, which cell design is used to minimize travel and material handling? A. U-Shape B. Circle C. Straight Line D. Converging Line

A. U-Shape

Which Visual Management visual cue is intended to communicate information, but not that an immediate reaction is required? A. Visual Display B. Visual Condition C. Visual Control D. Visual Target

A. Visual Display

What type of Kanban is used when one container of parts is to be moved to a production line or supermarket? A. Withdrawal Kanban B. One-card Kanban C. Kanban Square D. Two-card Kanban

A. Withdrawal Kanban

The rope in a theory of constraints system... A. controls material release duration in order to keep the buffer at a certain level. B. authorizes production. C. protects the pace. D. sets the pace.

A. controls material release duration in order to keep the buffer at a certain level.

The primary goal of Lean is to eliminate waste and... A. improve flow in the Value Stream. B. identify opportunities for inspection. C. increase the level of safety stock. D. reduce resources.

A. improve flow in the Value Stream.

A reliability metric suitable for longer periods of time but not useful for daily or weekly reporting is... A. mean time between failure (MTBF). B. overall quality rate. C. reliability rate. D. mean time to repair (MTTR).

A. mean time between failure (MTBF).

In a theory of constraints context, policies, rules, measurements, and training are examples of... A. non-physical constraints. B. organizational imperatives. C. physical constraints. D. things needing to be buffered.

A. non-physical constraints.

Another term for continuous flow is.... A. one piece flow. B. non stop production. C. inspection free material. D. zero maintenance time.

A. one piece flow.

Error Proofing is a technique used to make failure or potential failure easy to detect or to.... A. prevent it from occurring. B. rework it. C. redesign it. D. eliminate it.

A. prevent it from occurring.

An Error Proofing "control".... A. prevents a failure from moving forward until it has been corrected. B. provides only a signal that an error has occurred, but work can continue C. shuts down the process completely when an abnormality has been detected. D. lets the operator know the process is out of control.

A. prevents a failure from moving forward until it has been corrected.

In Visual Management, an example of visual display is... A. printed and posted metric charts. B. control charts. C. designated areas for inbound and outbound work. D. a shadow box containing all the necessary tools to complete the job.

A. printed and posted metric charts.

In a theory of constraints system, throughput of the process is determined by... A. the system constraint, or weak link. B. the money flowing out of the system. C. the money in the system. D. customer demand.

A. the system constraint, or weak link.

To prepare the work environment to contain visual information and controls, which one of the following Lean techniques is most widely used? A. Value stream mapping B. 5S C. Kaizen D. Mistake proofing

B. 5S

How is a Pull System different from a Push systems? A. A Pull System relies on a forecast or open capacity. B. A Pull System is dependent on actual customer orders. C. The process must continuously produce product to the maximum capacity of the line. D. There is no real difference; a Pull System functions similarly to a Push system.

B. A Pull System is dependent on actual customer orders.

When implementing Lean into office and service areas, one of the first steps is to fully understand the current business process. What Lean Six Sigma tool will help Lean practitioners define their specific process? A. The general business policy manual B. A process map C. Takt Time analysis sheet D. Utilization of the 5 Whys thought process

B. A process map

In Office or Service environments, how is waste typically eliminated and real value created for the customer? A. By adding redundancies for critical process steps B. By eliminating idle time, bureaucracy, unnecessary redundancy, and other non value-added activities C. By benchmarking with other organizations within your industry D. By optimizing the first step in the process

B. By eliminating idle time, bureaucracy, unnecessary redundancy, and other non value-added activities

Which of the following concepts results in fewer opportunities for operator error, improved quality output, and higher overall efficiency? A. Takt Time B. Continuous Flow C. Production Scheduling D. Value-added Processing

B. Continuous Flow

Which of the following best describes the type of maintenance that focuses on equipment improvements or modifications to prevent breakdowns or make maintenance easier? A. Breakdown Maintenance B. Corrective Maintenance C. Preventive Maintenance D. Equipment Maintenance

B. Corrective Maintenance

Which term describes the Six Sigma Methodology used for process improvement? A. Process Problem Improvement (PPI) B. Define, Measure, Analyze, Improve, Control (DMAIC) C. Process Quality Management and Improvement (PQMI) D. Design for Six Sigma (DFSS)

B. Define, Measure, Analyze, Improve, Control (DMAIC)

Which of the following roles often serves as the resource for removing roadblocks and resistance? A. Kaizen Team Leader B. Deployment Champion C. Kaizen Team Members D. Lean Leader

B. Deployment Champion

Which one of the following symbols denotes a decision point on a process map? A. Rectangle B. Diamond C. Oval D. Arrow

B. Diamond

Who is responsible for the sponsorship and commitment of an organization to the Lean Methodology? A. Kaizen Team Leader B. Executive Champion C. Lean Leader D. Project Champion

B. Executive Champion

In the office environment, a well-designed work area for co-located teams requires high cubicle walls to cut down on noise and allow for better concentration. A. True B. False

B. False

Which of the following is NOT among the three key techniques for improving a business transactional process? A. Eliminate redundancy such as requirements for multiple reviews and approvals, or duplicate copies B. Implementing the Current Value Stream map C. Eliminate bureaucracy and non-essential processing, especially if it is not an absolute requirement that can be justified D. Complete a Value Added Analysis to determine if work activity adds value to the service provided

B. Implementing the Current Value Stream map

In what type of process is the customer actually a part of the process? A. In a back office process B. In a service process C. In a workforce process D. In a manufacturing process

B. In a service process

A Kaizen Event... A. Is typically carried out over a period of a year or two. B. Is designed to produce rapid results. C. Implements improvements to the entire value stream at the same time. D. Comes from the Japanese word "Kaizen" meaning "the place where the truth can be found."

B. Is designed to produce rapid results

Which statement about Lean implementation is false? A. When Lean and Six Sigma are combined the results are powerful. B. Lean minimizes customer value and maximizes waste. C. Lean promotes shorter cycle times, faster process times, and higher quality. D. Lean implementation is appropriate for office and service organizations.

B. Lean minimizes customer value and maximizes waste.

What is the basic difference in detecting waste in manufacturing and transactional environments? A. Manufacturing waste is harder to quantify. B. Office output is often intangible and can take the form of information flow. C. In manufacturing it takes a SME to find waste and in the office it doesn't. D. There are no differences; waste is detected in the same manner regardless of environment.

B. Office output is often intangible and can take the form of information flow.

Cycle time loss due to equipment wear is identified and captured in which Overall Equipment Efficiency (OEE) category? A. Availability B. Performance C. Quality D. Overall

B. Performance

When Safety is included as the sixth S in a 5S effort, which of the following is an additional activity that may be included in the implementation? A. Remove visual display boards B. Properly store personal protective equipment C. Put in place audit procedure D. Institute changeover reduction

B. Properly store personal protective equipment

Which of the following is NOT a part of the A3 Countermeasures? A. Actions that address existing conditions B. Putting in place a one time permanent solution that solves the problem C. A temporary response until a better approach is found or conditions change D. Short term and long term actions

B. Putting in place a one time permanent solution that solves the problem

What are the primary benefits of eliminating or significantly reducing waste in an organization? A. There are no tangible benefits to the organization B. Reducing costs and increasing flexibility C. Leadership can raise the selling price of their products or service D. The customer is willing to pay more for the product or service

B. Reducing costs and increasing flexibility

In comparing Lean principles to Six Sigma principles, which of these statements is false? A. Six Sigma principles are problem-focused B. Six Sigma focuses on improving value streams C. Lean is focused on process flow D. Lean uses visuals to understand the process flow

B. Six Sigma focuses on improving value streams

Which of the following is the correct order of the 5S phases? A. Set in Order, Shine, Sort, Standardize, Sustain B. Sort, Set in Order, Shine, Standardize, Sustain C. Shine, Sort, Set in Order, Standardize, Sustain D. Standardize, Sort, Set in Order, Shine, Sustain

B. Sort, Set in Order, Shine, Standardize, Sustain

Which Lean tool enables flow by defining the sequence of steps and the time required to perform them? A. Visual Management B. Standard Work C. 5S D. Process Mapping

B. Standard Work

What is being described by the following? It tells a clear and concise story. It contains objective facts and data; not just speculation, but actual data based on observation. It solves a problem. A. The importance of a PDCA study B. The three critical components of a good A3 C. The best way to draw a Gemba roadmap D. The steps of a good root cause investigation

B. The three critical components of a good A3

Which of the following techniques is used to complement the Visual Management concept? A. SIPOC B. Tool locations that are clearly designated C. Cause & Effect Diagrams D. FMEA

B. Tool locations that are clearly designated

Standard Work Sheets contain Timing, Outcome and what other key component? A. Current State Value Stream Map B. Work Sequence: the step-by-step order of operations C. Inventory on hand D. The annual or semi-annual review date

B. Work Sequence: the step-by-step order of operations

Workplace Design is best described as... A. reducing the time and cost of transitioning a process from producing one product to producing a different product. B. a process for creating a workspace to enhance value by minimizing travel distances, eliminating waste, reducing lead times, improving teamwork, and gaining flexibility. C. having suppliers and customers share floor space with your company. D. designing the workplace to minimize people-related costs.

B. a process for creating a workspace to enhance value by minimizing travel distances, eliminating waste, reducing lead times, improving teamwork, and gaining flexibility.

Defects typically cause or result in... A. lower costs. B. added costs. C. higher profits. D. decrease of liability.

B. added costs.

Standard Work focuses on creating the... A. perfect way to perform work. B. best possible work method. C. way the Process Owners feel it should be done. D. way it was proposed for cost estimates.

B. best possible work method.

All of the following should be included in a process map except... A. available data, such as sigma level, COPQ, and defect rate. B. cause and effect relationships. C. the sequence of activities and decision points. D. rework loops.

B. cause and effect relationships.

Before beginning the actual task of mapping a process it is important to... A. define the number of decision points in the process. B. clearly define the boundaries of the process. C. identify all the inputs to each process step. D. identify which decision points lead to a previous step in the process.

B. clearly define the boundaries of the process.

In order to build stability in processes and create a foundation for improvement, Standard Work defines work activities for... A. suppliers and customers. B. content, timing, sequence, and outcome. C. sort, set in order, shine, standardize, and sustain. D. visual controls, displays, and metrics.

B. content, timing, sequence, and outcome.

A TOC tool which is used to examine the cause and effect logic behind the current situation and which helps determine why that situation is different from its preferred state is the... A. intermediate objective map. B. current reality tree. C. prerequisite tree. D. future reality tree.

B. current reality tree.

Think of 6S as the first layer of the foundation needed to support Total Productive Maintenance (TPM). The other foundational parts upon which TPM is built are the... A. maximization of profits and shareholder value. B. elimination of waste and continuous improvement. C. reduction of variation and efficiency improvement. D. complete training and reduction of loss time.

B. elimination of waste and continuous improvement.

Clearly defining the boundaries of a process... A. helps define customer requirements. B. helps prevent "scope creep." C. drives automation improvements. D. allows for management techniques to take effect.

B. helps prevent "scope creep."

A SIPOC is the first tool the team may use as it begins to identify process shortcomings that do not meet customer requirements and... A. suppliers that should be released from their contracts. B. inputs that do not meet its requirements. C. requirements that need to be renegotiated. D. outputs to slow down so the customers can handle them better.

B. inputs that do not meet its requirements.

An Error Proofing "alert".... A. prevents a failure from moving forward uncorrected. B. provides a signal that an error has occurred. C. shuts down the process completely when an abnormality has been detected. D. alerts management to visit the process.

B. provides a signal that an error has occurred.

One of the key ideas in Goldratt's theory of constraints is to maximize system performance by... A. balancing the production line, i.e., equal capacity at each operation. B. strengthening the weakest link the chain. C. maximizing production at each operation. D. minimizing the buffer.

B. strengthening the weakest link the chain.

When developing a process map... A. use standard operating procedures to validate the process. B. document only what you know of the process. C. "walk the process" in order to develop an accurate representation. D. document only what the subject matter expert told you to ensure accuracy.

C. "walk the process" in order to develop an accurate representation.

For a process running at the six sigma level of quality, which one of the following represents the equivalent Defects per Million Opportunities (DPMO) value? A. 66,810 B. 10,000 C. 3.4 D. 6,000

C. 3.4

When the term "Pull" is used in Lean thinking, who is ultimately doing the pulling? A. Downstream operations B. Takt Time C. Actual customer requests, orders, or consumption D. The cycle time

C. Actual customer requests, orders, or consumption

Which factor should be considered when selecting improvement projects? A. Order of project submittal B. The impact on the Human Resources department C. Alignment with business strategy and goals D. How success will be rewarded

C. Alignment with business strategy and goals

Which of the following is the best description of "waste" in Lean methodology? A. Low-cost / no-cost solutions that provide only a small amount of value to a product or service B. Small batch sizes that keep inventory/work moving through the system but are not as easy for batch operators as a large batch would be C. Any process activity that does not add value to the transformation of materials or information into a product or service delivered to a customer D. Utilizing a Pull system based on actual consumption doesn't prepare adequately for the "just in case" scenarios that inevitably arise.

C. Any process activity that does not add value to the transformation of materials or information into a product or service delivered to a customer

A Product Family refers to a group of products that go through the same or similar process steps, with similar process times and demand rates. How much of the same processing steps are usually shared? A. 100% B. At least 20% C. At least 80% D. At least 50%

C. At least 80%

Responsibilities for the improvement project will transition from the Improvement Team to the Operations Team in which DMAIC phase? A. Improve B. Analyze C. Control D. Define

C. Control

In which stage of the Six Sigma Methodology are the customer's requirements identified? A. Improve B. Analyze C. Define D. Control

C. Define

The SIPOC is often used in which phase of DMAIC because it helps process improvement teams generate the problem statement? A. Control B. Analyze C. Define D. Improve

C. Define

Which of the following will enable will enable flow? A. Supervising people B. Implementing a new inventory management system C. Eliminating sources of waste D. Reducing the number of your suppliers

C. Eliminating sources of waste

In which phase of implementing Standard Work does the team set expectations for the amount of time it should take to complete each activity? A. Develop Standard Work B. Implement C. Establish Goals D. Analyze Current Process

C. Establish Goals

Which step of the A3 process does the team define an ongoing process to ensure the gains obtained from the improved process are maintained? A. Background B. Countermeasures C. Follow-up D. Root Cause Analysis E. Current Condition

C. Follow-up

In which phase of implementing Standard Work is a communication plan for leadership and team members developed while making sure to set clear expectations for roles and responsibilities? A. Establish Goals B. Analyze Current Process C. Implement D. Develop Standard Work

C. Implement

In a production factory that has successfully implemented a Pull System, which of the following typically occurs? A. Increased prices B. Adding inventory to cover demand C. Less inventory D. Higher defect rate

C. Less inventory

In a 5S effort, what must be done before cleaning the work environment? A. Generate audit checklists B. Ensure the improvements are put in place as best practices C. Organize and arrange the items in the work place D. Maintain the improvements over time

C. Organize and arrange the items in the work place

In which phase of PDCA does the team implement the improved solution in full? A. Plan B. Do C. Check D. Act

D. Act

What difficulty is often experienced while implementing Lean within a typical office environment? A. Lack of potential solutions being identified B. Lack of sufficient waste for action to be taken upon C. Personnel do not welcome change. They are happy the way things are. D. Lack of business objectives

C. Personnel do not welcome change. They are happy the way things are.

Scrap and rework are part of which of the following categories of the Six Big Losses? A. Availability B. Performance C. Quality D. Overall

C. Quality

Which of the following statements regarding Six Sigma is correct? A. Applies only to manufacturing B. Works best in financial processes C. Reduces variation and eliminates defects D. Focuses only on statistical measurement

C. Reduces variation and eliminates defects

In the 5S process, visual controls that communicate how work should be done are implement in which phase? A. Sort B. Shine C. Set in Order D. Standardize E. Sustain

C. Set in Order

Which Lean tool is useful in mapping the flow of the information or product through the office process? A. SIPOC Diagram B. Future State Value Stream Map C. Spaghetti Diagram D. Swim Lane Diagram

C. Spaghetti Diagram

What is the overall focus of Visual Management? A. To highlight problem areas to expose waste in the process B. To promote delivery of products and services JIT C. To create an organized, clean, efficient workspace by ensuring standard practices are clear and visible to all D. There is no one overall or primary focus of Visual Management

C. To create an organized, clean, efficient workspace by ensuring standard practices are clear and visible to all

Which Lean technique is commonly used with 5S in the Set in Order phase? A. Flow and pull B. Changeover reduction C. Visual controls D. Error Proofing

C. Visual controls

In a Push System, works moves through the system based on... A. the customer. B. Cycle time. C. a forecast or open capacity. D. Takt Time.

C. a forecast or open capacity.

Total Productive Maintenance is best described as... A. reducing the time and cost of transitioning a process from producing one product to producing a different product. B. a process for creating a workspace to enhance value by minimizing travel distances, reducing lead times, improving teamwork, and gaining flexibility. C. a team and shop floor initiative focused on optimizing the effectiveness of manufacturing equipment. D. a limited scope improvement project intended to provide rapid results typically within one week.

C. a team and shop floor initiative focused on optimizing the effectiveness of manufacturing equipment.

Production equipment performance problems can be traced to six major losses. These include... A. failing to do, failing to plan, failing to act, failing to check, failing to track, and failing to report. B. motion, inventory, human potential, over production, defects, and waiting. C. breakdown loss, setup and adjustment loss, cycle time loss, machine stoppage due to parts shortages, startup rejects, and defect loss. D. lack of spare parts, under lubrication, management tampering, over adjustment, loose hardware, and lack of tools.

C. breakdown loss, setup and adjustment loss, cycle time loss, machine stoppage due to parts shortages, startup rejects, and defect loss.

In general, cell design guidelines are based on common sense and logic, easy access, error proofing, non-fatigue, and... A. how many people are on a work shift. B. where the document retrieval system is located. C. built-in organization. D. having enough space to store the inventory.

C. built-in organization.

Sub-optimization is likely to occur when departments or functions are centered around.... A. making deliveries. B. the customer. C. individual organizational goals. D. the flow of information.

C. individual organizational goals.

The buffer in a theory of constraints system... A. enforces the pace. B. authorizes production. C. protects the critical chain. D. sets the pace.

C. protects the critical chain.

An Error Proofing "shutdown".... A. prevents a failure from moving forward uncorrected. B. provides a signal that an error has occurred, but work can continue. C. stops the process automatically when a failure has been detected. D. lets the operator know that it is time to clock out.

C. stops the process automatically when a failure has been detected.

In the theory of constraints, the pace of a bottleneck production operation is controlled by the pace of... A. the previous (upstream) operation. B. the next (downstream) operation. C. the weakest link. D. another non bottleneck operation.

C. the weakest link.

Six Sigma has been described as a commitment to your customers, a statistical measurement of processes, and which of the following? A. A faddish theoretical method of quality management B. A way to increase variation C. A method to speed up the process D. A management framework for thinking about process economics, quality, and customers

D. A management framework for thinking about process economics, quality, and customers

Which Workplace Design outcome results from enabling work to move continuously from step to step, rather than requiring operations to stop and start? A. A flow and pull work area B. A cross-trained workforce C. A flexible workforce D. An optimized work environment

D. An optimized work environment

Which phase of implementing Standard Work observes work activities performed in multiple situations? A. Develop Standard Work B. Implement C. Establish Goals D. Analyze Current Process

D. Analyze Current Process

To calculate the required inventory for Flow and Pull Systems, organizations use the equation... A. Over Stock plus Buffer Stock plus Safety Stock. B. Cycle Stock plus Buffer Stock plus Extra Stock. C. Cycle Stock plus Quality Stock plus Safety Stock. D. Cycle Stock plus Buffer Stock plus Safety Stock.

D. Cycle Stock plus Buffer Stock plus Safety Stock.

The four phases of Standard Work are: A. Establish the Process, Analyze Goals, Develop Standard Work, Implement. B. Establish Standard Work, Analyze Current Process, Develop Goals, Implement. C. Establish Standards, Analyze Current Process, Develop Standard Work, Implement Goals. D. Establish Goals, Analyze Current Process, Develop Standard Work, Implement.

D. Establish Goals, Analyze Current Process, Develop Standard Work, Implement.

When implementing Lean which of the following creates value for the customer? A. By implementing a Push system B. By implementing faster cycle times for non value-added process steps C. By identifying the Current Value Streams in your company D. Giving the customer what they need, when needed, and of the quantity needed

D. Giving the customer what they need, when needed, and of the quantity needed

Which of the following is a benefit of the 5S phase Sustain? A. Improves productivity and workplace flexibility B. Places required tools and materials needed for the process step in easy reach of the worker C. Improves overall work environment D. Improves employee morale and builds self-discipline within the business culture to ensure 5S activities become habit

D. Improves employee morale and builds self-discipline within the business culture to ensure 5S activities become habit

Which of the following best describes the type of maintenance that focuses on minimizing required maintenance based on equipment design and/or installation? A. Breakdown Maintenance B. Corrective Maintenance C. Preventive Installation D. Maintenance Prevention

D. Maintenance Prevention

Lean transactional processes can be broken down into two primary functions. What are those two functions? A. Production, Accounts Payable B. Logistics, Management C. Human Resources, Finance D. Office, Service

D. Office, Service

The people needed to create a process map are: A. Consultants B. People independent of the process. C. Quality Control Experts. D. People involved in the process.

D. People involved in the process.

Which of the following is a Total Productive Maintenance goal? A. Reduce the annual maintenance budget B. Improve repair time C. Increase WIP inventory to cover downtime D. Prevent product defects and rejects based on equipment issues

D. Prevent product defects and rejects based on equipment issues

A tool which shows the inter-relationships of the steps in a process is called a... A. Cause & Effect Diagram. B. Control Chart. C. Pareto Chart. D. Process Map.

D. Process Map.

The team member most responsible for removing roadblocks and securing resources is the... A. Master Black Belt. B. Black Belt. C. Green Belt. D. Project Champion.

D. Project Champion.

Benefits from reducing variation in a process include improved process capability, decreased costs, and which of the following? A. A change of customer requirements B. Improvement of the company's culture C. A revised project charter D. Reduced Defects per Million Opportunities (DPMO)

D. Reduced Defects per Million Opportunities (DPMO)

Lean Goals can be achieved by which of the following? A. Decreasing waiting time by implementing a push system B. Instituting incoming inspection C. Adding more non value-added activities D. Reducing waste by using techniques like 5S

D. Reducing waste by using techniques like 5S

What does the "r" in SIPOCr stand for? A. Responsibilities B. Responses C. Request for Quote D. Requirements

D. Requirements

Which of the 5S/6S phases is being described by the following actions? Be sure file cabinets are not overloaded. Make sure that tripping hazards are eliminated. Keep emergency and medical supplies in clearly marked locations. A. Setup B. Security C. Satisfaction D. Safety

D. Safety

Which of the following is a characteristic of Visual Management? A. Self controlling B. Self managing C. Self directing D. Self explaining

D. Self explaining

A person waiting until the last possible moment before fully applying themselves to completing a task is an example of... A. multitasking. B. Parkinson's Law. C. suboptimization. D. Student Syndrome.

D. Student Syndrome.

What does SIPOC stand for? A. Supplier, Information, Process, Outputs, Customers B. Supplier, Inputs, Purpose, Outputs, Customers C. Scope, Inputs, Process, Outputs, Customers D. Supplier, Inputs, Process, Outputs, Customers

D. Supplier, Inputs, Process, Outputs, Customers

Which term best describes how team and shop floor associates work to maximize the effectiveness of equipment with the goals of preventing breakdowns and defects? A. SMED B. TAKT C. FIFO D. TPM

D. TPM

What is the importance about self regulating characteristics of Visual Management? A. To see that we have done more than the other workcells B. To ensure that everything was up to date last month when we last up-dated the visual management boards C. To visually identify that we achieved target last week D. To visually identify the current status of the work area, performance against plan, and replenishment status

D. To visually identify the current status of the work area, performance against plan, and replenishment status

The principle behind A3 is that everything you need to know about an issue or problem can be... A. solved by three Kaizen Events. B. stated in three words. C. determined by asking three Subject Matter Experts. D. captured on a single sheet of paper.

D. captured on a single sheet of paper.

Workplace Design relies on co-locating work processes to... A. enhance workspace utilization. B. accomplish zero inventory. C. increase ease of movement. D. improve communication and promote teamwork.

D. improve communication and promote teamwork.

In a process map the oval is used to... A. denote a process task. B. denote a decision point. C. identify defects in the process. D. indicate a starting or stopping point.

D. indicate a starting or stopping point.

Error Proofing is also called... A. prevention instituting. B. failure fixing. C. cause detection. D. mistake-proofing.

D. mistake-proofing.

When starting a typical office improvement project, the improvement team will often find that transactional processes are... A. better on second shift than on first shift due to less interruptions from handling customer inquiries. B. well defined or documented. As a result it is often easy to define defects or errors. C. running at peak efficiency and producing zero defects. D. not very well defined or documented. As a result it is often difficult to define defects or errors.

D. not very well defined or documented. As a result it is often difficult to define defects or errors.

The probability that a machine will run for a given amount of time without breakdown is called... A. availability. B. maintainability. C. quality rate. D. reliability rate.

D. reliability rate.

The drum in a theory of constraints system... A. enforces the pace. B. authorizes production. C. protects the pace. D. sets the pace.

D. sets the pace.

When creating a process map, the purpose of a walkthrough is to... A. check on the best time to set up interviews. B. understand who is working on value-added activities and who is not. C. collect audit artifacts and documentation samples to check against the master database. D. understand what is actually being done and why it is being done.

D. understand what is actually being done and why it is being done.