MFS526- Lean Operations Management

Which option below represents the most advanced form of flow? A. Complex B. Continuous C. Stable D. Consistent

B. Continuous

(T/F) According to Toyota the three levels of stakeholders are; 1) those who need to approve the final decisions, 2) . those who should provide input and 3) those who are impacted by the activity and therefore need to know about it beforehand

True

According to the definition of standardized work, STW is developed by: A. using the current best method for safe and efficient work B. requesting that upper management to define a standard for the work C. the engineer that plans the production. D. finding the best way to do a task

A. using the current best method for safe and efficient work

The Team Leader has two distinct areas of daily management responsibility; On-Line (which includes following process standard work & new member training) &_______________" A. Off-line (Assess, audit & track new TM training) B. Off-line (systematic problem solving) C. Off-line (Create Standardized work) D. Off-line (Develop TM skills)

B. Off-line (systematic problem solving)

Which form of waste consists of unnecessary walking, reaching, bending, or searching within a work station? A. Overprocessing B. Motion C. Overproduction D. Transportation

B. Motion

Which of the deliverables listed below are required for problem breakdown (step 2)? A. C/M ranking and plan B. Prioritized problem and Point of Occurrence C. Evaluate results & process D. large Gap & the standard

B. PP and PoO

According to Guiding Principle #1 (Customer viewpoint), what is the most important customer operators should focus on? A. the assembly customer B. the next process C. Final quality inspection D. the final customer

B. the next process

A traditional company's sales have struggled over the last few quarters. The warehouses are full of products, but they do not seem to be right products. According to Suzumura in Goroku #5, what is the cause of this issue? A. Poor forecasting B. Too long production lead times C. Inadequate production planning D. Lack of sales and operations planning

B. too long production lead times

According to the PS Culture module, making results and data visual and illustrating performance status clearly are part of which principle? A. Ownership and responsibility B. Visualization C. Thorough communication D. speedy action in a timely manner

B. visualization

Which of these is NOT one of the THREE elements of Standard work? A. Work Sequence B. Work Element Sheet C. Takt time D. Standard Work-in-process

B. work element sheet

What is the best definition of essential non-value added work? A. The customer is willing to pay for it and the form, fit, or factor is changed. B. Must be done to meet the customer's needs but does not add value. C. The customer is willing to pay for whatever you do but it may not add value. D. Adds no value and the customer is not willing to pay for it.

B. Must be done to meet the customer's needs but does not add value.

According to Fujio Cho in Seeds of Collaboration, Goroku 14, having a people friendly business philosophy is based on ____________. A. Economic Rationale B. Ethics C. Humanitarianism D. Reciprocity

A. economic rationale

As Cheryl points out in the Problem Solving Culture module, if you question the purpose and seek answers for your own work, you will... A. Produce the best product for your customer B. Find more time to relax C. Expect to rise more quickly in the company D. Always find the answers

A. produce the best product

Which option below is the strategy to create Smooth Flow? A. Reduce stagnation B. Eliminate processes C. Keep extra material at each station 'just in case' D. Provide extra manpower

A. reduce stagnation

What is the 2nd main point of Built in Quality? A. Self-Quality Check B. Necessary Conditions C. Fix the Problem D. Find the problem

A. self-quality check

Which of the following is not a part of the 5S's? A. Specialize B. Standardize C. Straighten D. Sort

A. specialize

Which member has the primary responsibility to respond and countermeasure abnormalities? A. Team Leader B. Team Member C. Group Leader D. Customer

A. team leader

Which of the following is not a purpose of an M&I? A. Tell workers process steps B. Identify problems C. Prioritize problems D. Understand relationship between processes

A. tell workers process steps

Which of the following is not a requirement of value added? A. The customer must request the change. B. The work must be done right the first time C. The product/widget must physically change. D. The customer is willing to pay for it

A. the customer must request the change

In the 8 Step Problem Solving process, we define the gap between current situation and the Standard as what? A. The large problem B. Target C. Root Cause D. Ultimate Goal

A. the large problem

According to the Drive and Dedication module, a major derailer for the 8 Step Problem Solving process is...(complete the sentence with the option that is most correct) A. the steps are not followed thoroughly. B. there is not visualization. C. the steps are not documented. D. there is poor communication.

A. the steps aren't followed thoroughly

Which is NOT one of the 7 wastes? A. Time B. Waiting C. Motion D. Overproduction

A. time

According to Suzumura in Goroku #5, which of the following is generally not considered in a traditional manufacturing environment? A. Timing B. Waste C. Safety D. Value

A. timing

What is the overarching purpose of an A3? A. to communicate B. to plan C. to measure success D. to provide accountability

A. to communicate

In Japanese, Yamazumi means; A. to pile or stack B. to annotate C. to graph & reflect D. make visible

A. to pile or stack

Within Toyota what does the acronym "TBP" stand for? A. Toyota Business Practice B. Total Business Perfection C. Total Best Performance D. Toyota Best Performance E. Total Best Practice

A. toyota business practice

Which of the following options best summarizes Goroku #2 on Monozukuri by Fujio Cho; that having a certain degree of ____________________ helps people pay attention and improves their problem solving capabilities. A. Urgency and Crisis B. Drills and Procedures C. Issues and Disturbances D. Stops and Starts

A. urgency and crisis

Which of the characteristics below are NOT a characteristic of a store? A. Min.Max quantities are defined & maintained B. Every product is available C. Includes the target cost of each product D. It is located as near as possible to the process that replenishes it E. FIFO is sustained F. Includes the designation locations for each product

C. Includes the target cost of each product

Which of the following is NOT an aspect of standardized work? A. Centered around human motion B. Produce at lowest cost C. Increase manufacturing D. Improve operations and minimize waste

C. Increase manufacturing

Which of the following is not one of the sub-points of Circle 2, "Self-Quality Check" in Built in Quality? A. Authority to stop the line B. Skill to judge C. Location to store defective products D. Well defined judgment standard

C. Location to store defective products

What is the TPS basic law which most directly relates to MIFC LT calculations A. pursue full work B. respect for people C. Produce to the pace of sales (takt time) D. reduce lead time

C. Produce to the pace of sales (takt time)

Which of the following is NOT characteristic of a pull process? A. Information flows form the customer upstream through the system B. Authorization for production and conveyance are required C. Production planning has to be done for each process step D. The end of the process features a finished goods store

C. Production planning has to be done for each process step

How can a company most effectively increase profit margins? A. Increase retail price B. Increase inventory C. Reduce waste D. Decrease number of workers

C. Reduce waste

Which best defines "Sweep" in the 5 S's? A. Only cleaning dirt and debris from equipment B. Sweeping the floors constantly C. Removing nonessential items from the work area D. The regimented, scheduled cleaning of the entire work area.

C. Removing nonessential items from the work area

What is the advantage of B-Type Pull System (Route-Specific or Sequence Production)? A. Does not requires a manifest or production list B. Short lead times C. Requires less WIP inventory between stations when there are many varieties D. Rapid adjustment to demand changes

C. Requires less WIP inventory between stations when there are many varieties

Which of the following is NOT one the three main elements of Pull System? A. Authorization B. Finished goods store C. Rework station D. Parts material stock

C. Rework station

According to True Lean thinking, before jidoka, just-in-time, or kaizen can be established, what foundation must first be laid? A. Specialization B. Industrialization C. Standardization D. Teamwork

C. Standardization

Which of the following statements is false? A. Standardization is setting a standard as well as bringing conditions into conformance with that standard. B. Standardization is also very useful in hospitals, offices or factories. C. Standards are absolute and unchanging D. First standardization prerequisite is a stable process.

C. Standards are absolute and unchanging

If a production line never stops and there are no mistakes or problems, assess what needs to happen next. A. Leaders from other lines need to go and see what is being done right on this particular line. B. It would be a good time to upgrade equipment to the more advanced. C. Standards need to be made higher to create a challenge. D. Team members need to partner with team leaders to see how they can maintain the line while eliminating processes.

C. Standards need to be made higher to create a challenge.

"Evaluate both Results and Processes" is which step of TBP? A. Step 6 B. Step 3 C. Step 7 D. Step 2 E. Step 1

C. Step 7

Which of the following scenarios best describes how visual management should be applied to a process? A. Visual cues shouldn't be used in busy work areas because they distract employees B. Visual cues should be used rarely to avoid clutter. C. Visual cues (such as labels and signage) should only be added to areas/items where it will add value. D. Visual cues (such as labels and signage) should always be added to every item in a work area whether it is stationary or not.

C. Visual cues (such as labels and signage) should only be added to areas/items where it will add value.

The two common Daily Management responsibilities from Managers to Team Members are? A. Determine strategic Activities of the group & create the Hoshin B. Manage firefighting activities & secure conditions for production C. Visualize conditions & Coach TMs to find root cause via problem solving (TBP & PPS) D. Ensure Standardized Work is followed & Conduct annual TM assessments

C. Visualize conditions & Coach TMs to find root cause via problem solving (TBP & PPS)

What type of Kanban Card can be thought of as a "transfer" card used by conveyance? A. Transport Kanban B. Production Kanban C. Withdrawal Kanban D. Pull Kanban

C. Withdrawal Kanban

All of the following are the advantages of standardized work, EXCEPT A. Produce product at the lowest cost B. Improve operations and minimize waste C. Eliminate unproductive employees D. Tool to build quality at each process

C. eliminate unproductive employees

In an ideal continuous flow system, cycle time should be _____ TAKT Time. A. Greater than B. Less than C. Equal to D. not related to

C. equal to

What is the primary improvement point for an unstable system? A. Increase the amount of WIP to protect the customer B. Hire new mangement C. Establish consistent / stable conditions D. Conduct a series of Kaizen activities

C. establish consistent/ stable conditions

What is the first step in building an M&I flowchart? A. Identify waste B. Ask questions C. Go and see D. Identify the material flow

C. go and see

In TPS a self-reliant workforce is an interconnected system consisting of Technical, Managerial & Philosophy, all focused on what key objective? A. Stability B. Customer satisfaction C. Human Development D. Reduced Costs

C. human development

In a True Lean system, process variations are generally; A. Due to errors in measurements B. Due to negligence of TMs C. Indicators of problems D. Neglected

C. indicators of problems

What is NOT important to visualize for Problem Solving? A. Current Situation vs Standard B. Target. C. Job instruction. D. Result and Process KPIs

C. job instruction

Standard work is the most effective combination of _________? A. time, energy, and space B. muri, mura, and muda C. people, materials, and equipment D. synergy, process, and ergonomics

C. people, materials, and equipment

In Ohno's Goruku #11 Education and Training - Education means to help someone discover unknowns, while ________ helps someone master what they know through __________ application. A. Answers, Repeated B. Reflection, Constant C. Practice, Repeated D. Repetition, Constant

C. practice, repeated

Choose the item described in the presentation as: "Key indicators for achieving Main KPI targets. (bigggest negative impact factors)" A. Hoshin B. Main KPI C. Sub KPI D. Process KPI

C. sub KPI

Muda refers to: A. Overburden B. 5S Activities C. The 7 Wastes D. Essential Non Value Added Work

C. the 7 wastes

What are you likely NOT to see in an M&I flow chart? A. Bottleneck B. Production and conveyance (material handler) batch or lot size C. The cost of individual components in the system D. Production times

C. the cost of components

According to Suzumura in Goroku 18, what should you do after completing a kaizen activity. A. Work to maintain that kaizen to ensure it doesn't fail at a later time. B. Present the results to higher management so it can be repeated. C. Work to kaizen what they just kaizened. D. Reflect on what was successful and allowed the kaizen to work out.

C. work to kaizen what they just kaizened

In Step 7 of Problem Solving, we evaluate the Results and Processes from these three viewpoints: The Customer's, The Company's and ________. A. The gap B. The boss C. Your own D. The target.

C. your own

From the options below, what is the relationship between a defect and the root cause according to Suzumura in Goroku 10? A. A single defects' root cause can be multifaceted B. None of the above C. A single defects' cause can never actually be found out D. A single defect will always have a single root cause

D. A single defect will always have a single root cause

Who uses A3 reports? A. Upper management when communicating to team members on the shop floor B. Group leaders and above C. Team members who want to communicate problems or ideas to their supervisors D. Anyone who needs to build understanding and/or gain agreement with others at any time

D. Anyone who needs to build understanding and/or gain agreement with others at any time

Which of the following is not one of the sub-points of Circle 1, "Necessary Conditions" in Built in Quality? A. Good process B. Capable Operator C. Good design D. Good Material

D. good material

There are 5 key points to to defining the layout of an A3 to fit your storyline. Which one below is NOT one of them? A. divide it into sections based on content B. tell the story sequentially from top to bottom, left to right C. title & number each section D. Include all data & facts you gather E. Title the A3 F. Give the most important information the most space G. limit the information to the essential points

D. include all data and facts you gather

Work that is regularly performed on an occasional basis compared to the standard work cycle is called ______________? A. non-standardized B. Changeover C. abnormal D. Periodic

D. periodic

What should one do when the Current Situation is meeting the defined standard of the company? A. Stop production until next shift. B. Continue working the same way. C. Conduct an appreciation meeting. D. Set a new target for the company

D. set a new target

After a successful process change is made, the next step should be to ________ the process. A. Change B. Implement C. Yokoten D. Standardize

D. standardize

The three interconnected components of a self-reliant workplace are; A. technology, waste elimination & standardization B. standardized work, heijunka & kaizen C. Productivity, Quality & Lead Time D. technical, managerial & philosophy

D. technical, managerial & philosophy

In True Lean, who should be primarily responsible/involved with process improvement? A. Suppliers and Customers B. Top management C. A designated company Lean specialist. D. The group doing the work

D. the group doing the work

Mr. Cho requested that Practical Problem Solving Training be developed for which of the reasons below? A. to place more emphasis on meetings and paperwork. B. to place more emphasis on writing good reports C. to keep people busy D. to place more emphasis on the actual observation of the problem

D. to place more emphasis on the actual observation of the problem

In the acronym "PDCA", how many steps of TBP are included in the "P"? A. 1 B. 6 C. 4 D. 3 E. 5 F. 2

E. 5

Which in not one of the 5 categories of Group Responsibilities? A. Productivity B. Human Resource Development C. Cost D. Safety E. Lead Time F. Quality

E. Lead Time

Which of the options below does the Performance Analysis Board help see that the Production Analysis Board cannot ? A. The plan based on actual capability of the process or line B. Actions taken when output is less than the plan C. Actions taken for abnormal downtime D. Output based on BNCT E. Gaps in production based on planned output vs actual

C. Actions taken for abnormal downtime

Is it always necessary to write an A3? Select the best response from the options below. A. An A3 is not always necessary because some problems are easily solved and going through the entire A3 process would be too complicated B. An A3 is always necessary as to ensure that the entire problem solving process is followed C. An A3 is not always necessary because some problems can be quickly solved but the A3 must be used as a check sheet and the fix must be standardized D. An A3 is always necessary to ensure the issue is well documented

C. An A3 is not always necessary because some problems can be quickly solved but the A3 must be used as a check sheet and the fix must be standardized

What is Necessary Non-Value Added Work? A. Activities that add form, fit, or function to the product B. Anything that takes time, resources, effort, or space, but does not add value to the product or service C. Any activity that is necessary under the current operating conditions, but adds no value to the product D. The minimum number of unfinished components necessary for the smooth completion of a work sequence

C. Any activity that is necessary under the current operating conditions, but adds no value to the product

Which of the following is not a function of Visual Workplace Management? A. Engage all levels of the team B. Drive activity C. Assign root blame. D. Set direction

C. Assign root blame.

Visual display/status boards are the result of Guiding Principle #4- Visualization. explain the purpose of displaying data visually for all to see. A. Displayed public data helps to give credit to the managers in the shop who are performing well. B. Displaying public data is supposed to be overwhelming so passerbys cannot interpret the data. C. Displaying public data allows anyone at anytime to see the status of the company. D. Displayed public data helps to see the red and green quicker, meaning the successful and failed results.

C. Displaying public data allows anyone at anytime to see the status of the company.

The four major steps to effective JI training are: 1) prepare the learner, 2) explain & show, 3) have the learner practice & provide immediate feedback & 4)? A. Put the learner on their own B. Create a training table C. Follow the learners progress D. Stress each point

C. Follow the learners progress

List the 8 guiding principles of 8-step problem solving

- Customer Viewpoint - Confirm the purpose of your work - Ownership and responsibility - Visualization - Judgment based on facts - Think and act persistently - Speedy action in a timely manner - Thorough communication

Name the 7 wastes

1. Waiting 2. Over Production 3. Rework 4. Motion 5. Over Processing 6. Inventory 7. Transportation

What waste can be considered as the "mother of all wastes"? A. Overproduction B. Inventory C. Overprocessing D. Defects

A. overproduction

List the 7 basic components of a True Lean operations environment (from model 7 (slide #6) in TPS overview from true Lean & OMDD perspectives)

- To get highest customer satisfaction you need effective 8-step problem solving. - For effective 8-step P/S you need to be able to eliminate abnormalities. - In order to manage abnormalities you need to establish Standardized Processes. - In order to achieve and maintain Standardized Processes you need Engaged Staff. - To have Engaged Staff you need to define Clear Roles - To define Clear Roles you need to have Management Support Culture

The appropriate KPI level for Team Leaders are? A. Process KPIs B. Shop KPIs C. Strategic KPIs D. Group KPIs

A. process KPI

Name the 8 steps of the 8-step PS method

1. Clarify the Problem 2. Breakdown the Problem 3. Set a Target 4. Root Cause Analysis 5. Develop Countermeasures 6. See Countermeasures Through 7. Verify Both Results and Processes 8. Standardize Successful Processes

Match the following TBP steps to their corresponding activities: Step 1 Step 2 Step 3 Step 4

1. Clarify the problem 2. breakdown the problem 3. set a target 4. analyze the root cause

List the 4 philosophies of TPS & an example of how each is applies in the TF/class

1. Customer First 2. People are the most important resource 3. Kaizen or continuous improvement 4. Shop floor focus

What are the key points to maintain a shop floor focus?

1. Management must go to the floor to confirm conditions with their own eye. (Facts are more important than data. Management only exists to support the shop floor jobs.) 2. Management is responsible to develop TMs 'eye' and skill to see actual conditions 3. Give all members the ability to take action

List the 8 true lean operating philosophies

1. No Standardization = No Kaizen 2. There is only one best way to do something, we don't know what it is so we will standardize what we currently do and improve on that 3. Go see for yourself (Genchi Genbutsu) 4. Each group is responsible to improve their work 5. We will problem solve using FACTS 6. True Countermeasure: Will permanently keep the abnormal condition from returning 7. The customer must never suffer poor quality - The next process is the customer 8. Graphs and data show the group their improvement opportunities, not upper management

List the 3 Basic laws and the main tools/strategies to implement them

1. Produce at Takt Time (Takt time is the pace of sales.)-----+ ID Takt Time & use Standardized Work & the Pull System to meet it 2. Reduce Lead time---+ Develop visual system to enable CI based on effective PS 3. Pursue full work---+ Design out overburden (muri) and inconsistency (mura), and eliminate waste (muda).

List the 5S's and the actions associated with each one

1. Sift---separate essential/non-essential items 2. Sweep---remove non-essential items from work place 3. Sort---organize essential materials 4. Sanitize---Standardize cleaning procedures 5. Sustain---Perform on ongoing systematic basis

According to Suzumura in the SoC Goroku #7, when an order is made for 1000 units but we can only make 800 it is known as which of the following? A. Opportunity loss B. Order Loss C. Absolute Loss D. Production Loss

A. opportunity loss

At which Step in the 8-Step P/S method should the question "Why" be asked? A. 2 (Problem breakdown) B. 6 (Validating the countermeasure) C. 1 (Clarifying the problem) D. 4 (Root Cause analysis)

D. 4

What is the target for fluctuation in normal CT? A. 5% B. 0% C. 20% including unplanned occurrences D. < 10%

D. <10%

Problems are a path towards___________? A. profitability B. the seven wastes C. greater costs D. improvement

D. Improvement

According to the definition of Job Instruction (JI), the the purpose of JI is to get someone to do a particular job Safely, Correctly & ________? A. better than everyone else B. Quickly C. Within Takt Time D. Consistently

D. consistently

Which option below is the basic strategy to create Continuous Flow? A. Respond to customer immediately B. Increase TM morale C. Increase TM training D. Eliminate stagnation completely

D. eliminate stagnation completely

(T/F)In a True Lean environment, Graphs and data show improvement opportunities, not management.

True

*blank question*

True

What is the exact meaning of "True Lean?"

The group by themselves, using systematic problem solving to improve the work they do towards the achievement of the company's targets and goals when and only when the company culture is the reason the improvement occurs.

What is the Operational Requirement and Strategy to achieve True Lean for the group? List and discuss the two basic strategies and how they were applied in the Ticket Factory

The two basic strategies are; 1) eliminate waste and 2) ensure quality 1: Eliminate Waste: Key Points: The use of 5S, visual management, STW and P/S to eliminate Waste in the TF. 2: Enable Quality: Key Points: The idea of built-in-quality at each station; the need for each TM to know what a good part looks like, and be able to tell if they are making good or bad parts in real time.

(T/F) Are the following primary considerations when writing an A3 correct? 1) is the key message clear? 2) are the analysis clear and does it lead to the intended conclusion? 3) is it fact based? 4) are there any contradictions in the reasoning? 5) Is the information concise and able to be presented in 10 minute or less?

True

(T/F) Major formatting considerations include; 1. define the layout according to the intended story 2. make it simple and easy to read 3. visualize the information as much as possible (pictures, graphs, models, charts etc) 4. Finalize the details--include the author's name, department, date and document path

True

(T/F) Nemawashi is a gardening term meaning going around the roots. In a business context it refers to the a method of doing groundwork and fertilizing ideas to help them take root and grow.

True

What is NOT a trait of value added work? A. The work is done faster than it would be done in a standardized process. B. The customer must be willing to pay for it C. The work must be done correctly the first time. D. The form, fit, or function of a thing is changed

A. The work is done faster than it would be done in a standardized process.

What are the 6 levels of visual management

1. Share Information 2. Share standards at the site 3. Build standards into the Workplace 4. Warn about abnormalities 5. Stop abnormalities (prevent defects from moving on) 6. Prevent abnormalities from occurring (Error-proof)

What is the main cause of material stagnation? A. Varying speeds of production cycle time B. Standardized work C. Too many forms of information D. Varying speeds of receiving information

A. Varying speeds of production cycle time

Which of the following drives a pull system? A. Customer orders B. Management directives C. Lead time D. Ability to cover for equipment downtime

A. customer orders

According to Goroku # 13, per Cho, when is the best time for Kaizen and why? A. When the economy is slow because there is more time available to try solutions B. When the economy is slow because it is easier to find workers C. When the economy is growing because there is more money available for solutions D. When the economy is growing so that solutions will help as production is ramping up

A. When the economy is slow because there is more time available to try solutions

The "Toyota Way of Shop Floor Management" is A. Abnormality Management B. Management by Objective C. Hour by Hour Management D. Problem Delegation Management

A. Abnormality Management

According to Suzumura in Goroku #4, what distinguishes an amateur from a professional? A. Amateur will seek find the easy way out while a professional will return to the basics. B. A professional will seek advanced training where an amateur will return to the basics. C. Challenges are easily mastered by a professional. D. A professional trusts Kaizen will be done by the amateurs so they can learn

A. Amateur will seek find the easy way out while a professional will return to the basics.

Mr. Hayashi's directed the North American press shops to do two things, 1) to utilize the PAB and 2)? A. Check production on the shop floor every day B. Ensure operators are performing standardized work C. Conduct systematic problem solving daily D. Determine the impact of North American production on Toyota global

A. Check production on the shop floor every day

Which of the following is NOT necessarily a sign of instability? A. Cycle times vary somewhat when performing standard work B. Team members are not present at their stations during work hours C. Parts are not available when needed D. Abnormal work being done

A. Cycle times vary somewhat when performing standard work

Which of the options below does a Production Control Board (PCB) help see? A. Gaps in production based on planned output vs actual B. Where problems are located C. Actions taken when output is less than the plan D. If a specific countermeasure has been effective E. The Point of Occurrence of problems

A. Gaps in production based on planned output vs actual

What is the condition for a type A or part-specific pull system? A. High volume low variety B. Low volume low variety C. Low volume high variety D. High volume high variety

A. High volume low variety

Which option below states the main reason Mr. Hayashi wanted the North American press shops to utilize the PAB? A. Its important to see the plan (based on BNCT) vs Actual output B. The see which countermeasures were most effective C. Understand how current production conditions impacted Toyota global D. Allow managers to see which lines/processes were under performing

A. Its important to see the plan (based on BNCT) vs Actual output

What is NOT a requirement to effectively implement a Pull system? A. Low productivity B. Rapid changeover C. good standardized work D. built-in-quality

A. Low productivity

What do angry clouds represent? A. Material & Information flow stagnation points B. How information move C. Problem countermeasures D. How material moves

A. Material & Information flow stagnation points

Which of the items below are used to "Drive Action for Management of Physical Goods" in the Visual Workplace Management System? A. Min/Max standards B. An empty container placed in the aisle. C. Customer complaints D. A note from the Team Leader of the previous shift

A. Min/Max standards

The role of ______ is to ensure consistency and approach across all work groups, ensure that operators are conforming to the standardized work sequence, and to provide appropriate guidance and support for continuous improvement and re-balance activity. A. Production Management B. Team Leaders C. The CEO D. Team Members

A. Production Management

The 3 Basic TPS laws are; Produce at the pace of sales, Reduce lead time &________________ A. Pursue full work B. reduce costs C. Follow standardized work D. eliminate waste

A. Pursue full work

What are two primary reasons to build consensus inside Toyota? A. Respect for people and continuous improvement B. To ensure the workforce is happy C. To ensure the best decisions are always made and reduce cost D. To help keep unions from taking hold inside Toyota

A. Respect for people

According to the 'new' Toyota House, the foundation of TPS is; A. Stability B. Standardized work C. Jidoka D. kaizen

A. Stability

Who's viewpoint is the most important in determining waste? A. The customer B. Supplier C. Management's D. Operator

A. The customer

The purpose of M&I flowchart is to witness what in the current situation? A. The status towards meeting Just-In-Time production B. ability to perform Jidoka C. Visual Management D. Genchi Genbutsu

A. The status towards meeting Just-In-Time production

Which of the following options are NOT listed as part of the Job Breakdown Form A. Manager's Name (Who) B. Key Points (How) C. Major Steps (What) D. Reasons (Why)

A. Who

In Goroku #9, Fujio Cho postulated that the development of people can be done using only two questions. What are these two questions? A. "Where is the problem?" and "What?" B. "Did you see it?" and "Why?" C. "When did the problem occur?" and "Who?" D. "Can you fix it?" and "Do you need help?"

B. "did you see it?" and "why?"

Rank the order of importance from most to least of the following activities according to Ohno in Goroku 15. A. Actions>words>observations B. Actions>observations>words C. Words>actions>observations D. Observations>actions>words

B. Actions>observations>words

PPS is used for which type of problem? A. A "big picture" problem. B. An urgent problem that just happened that you saw with your own eyes.​ C. A broad, general problem found in data from last week's production. D. A problem that fits into the A3 format.

B. An urgent problem that just happened that you saw with your own eyes.​

The four actions taken to "get ready to instruct" include; 1) Have a planning time table, 2) Have the workplace properly arranged, 3) Have everything ready, & 4)? A. Have the standardized work chart available B. Break down the job C. Provide an outline of all the processes in the line D. Be sure your manager knows the plan

B. Break down the job

How does a kanban system discourage overproduction? A. By making information visible B. By providing the authorization to build in a controlled manner C. By encouraging one piece flow D. By linking materials and information

B. By providing the authorization to build in a controlled manner

What is NOT done when negative results occur in Step 7? A. Redo Step 4 (root cause analysis) B. Change the prioritized problem from Step 2 (Problem Breakdown) C. Set a different target (Step 3) D. Consider another counter measure (Step 5)

B. Change the prioritized problem from Step 2 (Problem Breakdown)

The three primary things Mr. Hayashi specifically requested to be checked daily were cycle time, downtime & A. wait time B. Changeover time C. the amount of rework D. the number of defects

B. Changeover time

What is Type 3 standard work? A. Work is not repeatable and there is no cyclic work that can be established. B. For processes which cannot be set to takt time since they are not operating in a 1 by 1 flow. They involve repeatable work, often with long cycle times C. Repeatable cyclic work sequences can be established without any cycle time variations D. Repeatable cyclic work sequences can be established and variations exist that affect the cycle time

B. For processes which cannot be set to takt time since they are not operating in a 1 by 1 flow. They involve repeatable work, often with long cycle times

The fourth guiding principle is visualization, which stipulates that data must be understandable to the work group. An example of this is the use of KPIs. This is important because... A. It holds workers accountable. B. It unites the company's success to that of the team members. C. It allows true countermeasures to be implemented more quickly. D. It improves workers morale.

B. It unites the company's success to that of the team members.

Which is NOT one of the 4 philosophies of the TPS according to OMDD? A. Customer First B. Management by Authority C. Elimination of Waste D. Respect for Humanity

B. Management by Authority

According to Goroku #6, products should be made at pace with sales which means equipment should not be run at full capacity (100% Rate of Operation) to meet demand but rather be able to achieve 100% Operational Availability (probability the machine will be able to operate when needed). Doing that will.... A. Ensure adequate stock is on hand whenever there is a demand for it. B. Require effective preventive maintenance and minimal set-up times. C. Increase costs because products will not be made efficiently. D. Maximize efficiency and allow team members a chance to rest once their quota is met.

B. Require effective preventive maintenance and minimal set-up times.

In the TPS tool, "Work Balance Chart" what does the "star" symbol represent? A. total downtime B. The actual rate of output C. The stretch target D. The slowest cycle of the run E. The best cycle time of the run

B. The actual rate of output

An M&I flow chart is a visual representation or map showing the movement of material and information: A. Leaving out other details such as problem areas or issues. B. Through a defined series of processes over a period of time. C. With respect to resources invested in each D. With the customer on the left and the supplier on the right.

B. Through a defined series of processes over a period of time.

What is commonly known as the 8th waste? A. Waste of movement B. Waste of underutilized skills and talents C. Waste of inventory D. Waste of rework

B. Waste of underutilized skills and talents

Under which conditions below is a Type B or route specific kanban system more advantageous than a Type A or part specific kanban system? A. When there is a push system in place. B. When product variety and count is high. C. When team member cannot identify difference between each product variety from a part specific kanban codes D. When WIP is segregated by color or type

B. When product variety and count is high.

According to the Role Definition, of the 4 possible Role Functions stated below, which is NOT correct? A. What you do B. Where you do it C. How you do it D. Why you do it

B. Where you do it

Operation Availability is? A. The amount of material available for use B. Actual output / Planned output C. The amount of Wait Time / Run Time D. The percentage of machine usage

B. actual/planned

Which is the closest definition of tatakidai? A. document for final approval B. beat-up document or bashing draft C. going-around document D. outline

B. beat-up document

Using Fujio Cho's Goroku (#1) on Running the Company, Management MUST ____________ preach their vision on corporate long-term plans. A. Urgently and Desperately B. Constantly and Continually C. Deliberately and Dramatically D. Softly and Tenderly

B. constantly and continually

Which Leadership Development Stage introduced the TWLL is most strongly supported by Cho's statements in Goroku #18 about going after the "head" of the Kendo player? A. Support Daily Kaizen B. Create Vision and Align Goals C. Coach and Develop Others D. Self-Development

B. create vision and align goals

What is the actual time it takes to process 1 unit defined as? A. Available Production Time B. Cycle Time C. Takt Time D. Jidoka Time

B. cycle time

According to the 8-step Problem Solving Culture module, which of the following is NOT one of the Guiding Principles for PS? A. Have a customer-first mentality B. Ensure all T/Ms are training on PS C. Always try to make conditions visible D. Make judgement based on facts

B. ensure all T/M's are training on PS

Guiding Principle #5 indicates that Gemba Walks are supposed to help everyone make judgement based on _______. A. the supervisor's perspective B. Facts. C. Others experiences D. Team members opinions.

B. facts

Failure to follow standardized work sequences doesn't lead to: A. Defects B. Just in Time production C. Cycle Time Fluctuation D. Missing steps in the sequence of operations

B. just in time production

What does the Visual Workplace Management System (VWMS) use as indicators of specific targets which are deemed critical to the organization as identified in the Hoshin? A. Sub-KPI's B. Main KPI's C. Process activities D. Process KPI's

B. main KPI's

the main components of stable processes are: A. takt time, jidoka, JIT and Kaizen B. man, methods, materials and machines C. JIT, pull, kanbans & continuous flow D. pull, takt time, heijunka & standardization

B. man, methods, materials and machines

Material LT is the # of pieces of material ____________? A. divided by the takt time B. multiplied by the takt time C. divided by the cycle time D. multiplied by the cycle time

B. multiplied by the takt time

The most difficult type of work to standardize is A. Short cycle variable work B. Office/creative work C. Repetitive single cycle work D. Long cycle variable work

B. office/creative work

In what order should the equipment and production method be decided? A. It depends on each situation since no two situations are the same B. Production method and then the equipment C. The order doesn't matter, but rather the ability of the two to work together. D. Equipment and then the production method

B. production method and then the equipment

Select the item below that is used to "Drive Action regarding Work (People)" in a VWMS. A. Opinion Surveys B. Quality Check Standards C. Plant closure due to a snowstorm. D. Wrong parts from a supplier.

B. quality check standards

What is the first step to drive activity in the VWMS? A. Send out a customer survey to find out what the customer thinks our problems are. B. recognize the gap or the abnormality. C. Take a team member off the line so you can assign activity to them. D. Ask for an assignment from the manager of the area.

B. recognize the gap or the abnormality.

If a standard is not defined, then we must _________. A. Perform a performance analysis on current situation. B. Standardize the current situation. C. Conduct Problem Solving to determine the standard. D. Have an engineering study completed.

B. standardized the current situation

What is the starting point for job instruction? A. 5S B. standardized work C. Practical Problem Solving D. Visual management

B. standardized work

In Step 1, Clarify Problem, of 8-step problem solving, the ultimate goal is not measurable. Why? A. the ultimate goal is measurable B. Since the ultimate goal is only theoretically possible, and is not achievable in practice, there is no reason to measure it C. It can be demotivating if you can never achieve the ultimate goal D. If you put a measure on the ultimate goal and meet it, there will be no more incentive to improve

D. If you put a measure on the ultimate goal and meet it, there will be no more incentive to improve

The tatakidai is used to______________. A. explain the team members ideas to team leaders and group leaders B. To submit to your ideas to management for approval C. Used to initiate discussions for funding options D. Initiate discussion with your stakeholders

D. Initiate discussion with your stakeholders

According to guiding principle #8 - Thorough Communication, why is communication so important to successful problem solving? A. It allows HR to monitor team activities B. It ensures everyone is on the same page initially. C. It gives leaders an opportunity to display their accomplishments, promoting pride. D. It promotes ownership, participation and buy-in.

D. It promotes ownership, participation and buy-in.

the 4 Ms of stability include Man, Machine, Materials & _______________? A. Manpower B. Morale C. Management D. Method

D. Method

Which item below does not drive us to take action regarding information management? A. Sub-KPI - Target gaps B. Hoshin / Business Plan - Goals C. Main KPI - Target Gaps D. Process KPI's that don't have a gap

D. Process KPI's that don't have a gap

Which of these is a disadvantage of A-type (part-specific) Pull system? A. Rapid adjustment to demand changes B. Standardized conveyance C. Short lead time D. Requires inventory of all varieties

D. Requires inventory of all varieties

A company consistently generates scrap material from a given process. What element of 5S should they observe in order to address this issue? A. Seiton (Straighten) B. Seiketsu (Standardize) C. Seiri (Sort) D. Seison (Sweep/Shine)

D. Seison (Sweep/Shine)

What are the two requirements to most effectively use the PAB? A. Good visual management & the team leader B. Change Overs (C/O) and a multipurpose line C. Standardized work & 5S D. Standardized work & the Team Leader role

D. Standardized work & the Team Leader role

On the production line defects have been found. From Goroku #10, what does Suzumura say should be done when a defect is found and why? A. Stop production and collect data on the defect as this will help to find the root case B. Take the defect off the line and continue production and then continue to monitor and collect data as this help identify the root case C. Stop production and fix the defect on the spot and continue production as now that the defect is fixed, it should not surface again D. Stop production, do root cause analysis, and implement a countermeasure because it is much easier to find the root cause as soon as the defect occurs

D. Stop production, do root cause analysis, and implement a countermeasure because it is much easier to find the root cause as soon as the defect occurs

Which of the following is not something that a leader must make sure is implemented for standardized work? A. A commitment to continuously improve standards B. A quick response system is in place C. Blame free culture D. Strict control regiments to insure the system has no downtime

D. Strict control regiments to insure the system has no downtime

Which of these is NOT a part of the operations shift that you would expect in a Lean System? A. Quick containment of all abnormal work B. Abnormal conditions are clearly visible C. Standardization to prevent recurring problems D. T/Ms do both normal and abnormal work

D. T/Ms do both normal and abnormal work

Of the following, which is NOT a pre-requisite of Standardized Work? A. Centered around human movements B. Minimal trouble with machinery or equipment C. Minimal fluctuation in the operation of equipment or production time D. Takt time being less than cycle time

D. Takt time being less than cycle time

Why should we adopt or create a standard for Workplace Visual Management? A. To establish criteria level for our genchi genbutsu B. To establish the plan for eliminating/minimizing Muri, Mura and Muda C. To establish the abnormal level we plan to accomplish D. To establish and support the ability to perform 'normal' work.

D. To establish and support the ability to perform 'normal' work.

The process of communicating information to the workplace, individual processes to maintain standards, and guide problem solving activity is known as? A. Visual Control B. Productivity C. Visual Management D. Visual Display

D. Visual Display

According to Ohno in Seeds of Collaboration Goroku #4, what two factors should decisions be based on? A. Better business performance and shorter lead times B. Better business performance and shorter cycle time C. Whether it reduces cost and results in headcount reduction D. Whether it reduces cost and leads to better business performance

D. Whether it reduces cost and leads to better business performance

According to Suzumura in Goroku 16, which of the following situations drives the most effective Kaizen? A. Complete knowledge of a situation and time to explore it B. Expensive high-end machines and well trained employees C. Sufficient budget and a good kaizen schedule D. A need and lack of money

D. a need and lack of money

What best describes what an A3 report is? A. A way to allow team members to communicate with upper management B. A special report used to communicate between various Toyota manufacturing plant managers C. a comprehensive report using as many 11x17 pages as needed for each topic D. a one-page report that derives its name from the size of the paper used for the document

D. a one-page report that derives its name from the size of the paper used for the document

According to Mr. Hayashi, OA (Operation Availability) is what? A. a way to directly measure standardization B. the best way for team members to identify problems C. a means to find the Point of Occurrence of a problem D. A result KPI

D. a result KPI

According to Taiichi Ohno in Goroku #10, a leader should ask "why?" how many times in order to get to the root cause of a problem? A. Twice B. Four Times C. Three Times D. Five Times E. Once

D. five times