Lean Implementation | Lean 101 Question and Answers


Lean Implementation | Lean 101 Mock Test

lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.

 



 

1
Defect prevention is
a. Mistake proofing
b. Iterative testing
c. OA
d. Early testing

Answer : Mistake proofing
2
______________ is the critical starting point of Lean thinking
a. Project Value
b. Customer Value
c. Value Addition
d. Program value
Answer : Customer Value
3
To get First Hand Information, we need to do
a. Visual Control
b. Go See Yourself
c. Brainstorm
d. Continuous Monitoring
Answer : Go See Yourself
4
Value is always defined from the perspective of the
a. Customer
b. Project
c. Product
d. All of the above
Answer : Customer

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5
______________ is a Visual Control device in the work area indicating a process or quality problem
a. Andon Board
b. SMED
c. Both 1 and 2
d. None

Answer : Andon Board
6
______________ is the rate (time per unit of value) at which work should proceed through a Value Stream
a. Cycle Time
b. Activity Time
c. Takt Time
d. All the above
Answer : Takt Time
7
This technique can be used to conduct root cause analysis
a. 5 Why
b. Fishbone diagram
c. Cause and Effect diagram
d. All the above
Answer : All the above
8
Pull system helps in avoiding ______________
a. Over production
b. Slow production
c. Fast production
d. None of above
Answer : Over production
9
Placing everything in its place is part of _________________in 5S framework
a. Sort
b. Straighten
c. Shine
d. Sustain
Answer : Straighten



10
Creation of a level schedule by sequencing orders in order to smoothen the demand is known as ______________
a. Heijunka
b. Gemba
c. Kaizen
d. Hoshin Kanri
Answer : Heijunka
11
Kaizen as implemented in Lean helps in the following
a. Ongoing improvement
b. significant onetime improvement
c. Ongoing small changes suggested by external process consultant
d. One time significant change suggested by external process consultant
Answer : Ongoing improvement
12
Continuous organization learning and improvement is ensured through ______________
a. Standardization and Automation
b. Retrospection and Mistakeproofing
c. Pull and Flow
d. Retrospection and Kaizen
Answer : Retrospection and Kaizen
13
Main purpose of Visual control is to
a. Create dashboards and metrics for measurement
b. Ensure problems are not hidden
c. Help in baselining and measuring the trends
d. Showcase to the management on the success stories of the team
Answer : Ensure problems are not hidden
14
VSM helps in
a. Identifying areas where automation can be implemented
b. Identifying areas for putting mistake proofing process
c. Identifying value adding and non value adding activity in a process
d. Identifying areas where Visual control can be implemented
Answer : Identifying value adding and non value adding activity in a process
15
PDCA stands for
a. Plan-Do-Check-Act
b. Plan-Do-Control-Analyze
c. Plan-Do-Check-Analyze
d. Plan-Do-Control-Act
Answer : Plan-Do-Check-Act
16
Which of the following is not a root cause analysis technique
a. Pareto diagram
b. 5 Why
c. Fish Bone Diagram
d. Mistake Proofing
Answer : Mistake Proofing
17
The culture of Lean gives a lot of importance to
a. Innovation
b. Capability building
c. Questioning status-quo
d. Showcasing best practices
Answer : Questioning status-quo
18
Identifying the necessary and removing unwanted one in any workplace is called
a. Straighten
b. Automation
c. Mistake proofing
d. Sort
Answer : Sort
19
What is the typical first step towards identifying the area of waste elimination in a project
a. Root Cause Analysis
b. 5S
c. Mistake proofing
d. Value Stream Mapping
Answer : Value Stream Mapping



20
Kaizen applied with the right approach helps in achieving
a. Quantum improvement
b. Incremental improvement
c. Sustains the performance
d. Marginal improvement
Answer : Incremental improvement
21
‘Value’ in Lean terms is a deliverable to the client which is usable. Identify which statements below qualify for this Value definition
a. Value for a recruitment group is each human resource made available to the project teams
b. Value for a Maintenance project is the Bugs serviced per release
c. Value for a Conversion project is every web page converted
d. All of the above
Answer : All of the above
22
Identify Type 2 “Waste” in these scenarios
a. Waiting and searching for resources in the lab during reproduction and testing
b. Capturing relevant information in defect tracker
c. Updating knowledge base
d. Frequent build cycles, frequent code reviews and early testing
Answer : Waiting and searching for resources in the lab during reproduction and testing
23
Workload leveling is
a. Assiging important tasks to key resources only
b. Allocating the tasks as and when they queue up
c. Allocating the right tasks to team members based on effort,complexity estimates, skill level
d. Dividing and assigning the same tasks to multiple people
Answer : Allocating the right tasks to team members based on effort,complexity estimates, skill level
24
What is Lean?
a. Creating value from the perspective of a customer
b. Improving processes and operation
c. A culture of continuous improvement
d. All of the above
Answer : All of the above
25
When should I start implementing Lean principles in a project?
a. When the organization mandates
b. When there is a problem in the project
c. When the project gets kicked off
d. None of the above
Answer : When the project gets kicked off
26
During which phase of the project can Lean be implemented?
a. Requirement phase
b. Design phase
c. CUT & ST phases
d. All of the above
Answer : All of the above
27
The delivery team uses white boards to monitor the status of the tickets, automates routine jobs, maintains checklist and implements learning from previous releases. The team does not have a knowledge of Lean and has never attended any Lean training sessions. Is Lean being practiced in the project
a. Yes
b. No
c. Can’t answer
d. None of the above
Answer : Yes
28
The management decisions in a company practicing Lean philosophy is based on
a. Waste elimination
b. Short term financial gains
c. Long term thinking even at short term financial expense
d. Medium term thinking but with high operating margins
Answer : Long term thinking even at short term financial expense
29
Which of the following are two key pillars of the Toyota Production System?
a. Just-in-Time and Waste Elimination
b. Jidoka and Just in Time
c. Visual Management and Kaizen
d. Standardisation and Leveled Production
Answer : Jidoka and Just in Time



30
The culture of stopping when there is a quality problem is called
a. Waste elimination
b. Standardisation
c. Jidoka
d. None of the above
Answer : Jidoka
31
Which of the following is a technique involving simple inexpensive automatic mechanisms or manual inspection in a station, that makes the quality issues obvious at a glance?
a. Visual Control
b. Value Steam Mapping
c. both 1 and 2
d. Poka Yoke
Answer : Poka Yoke
32
The roots of Lean thinking can be traced back to
a. Harvard
b. GE
c. Honda
d. Toyota
Answer : Toyota
33
Lean principle is based on management decisions adopting a _____________ philosophy”
a. Short Term
b. Medium Term
c. Long Term
d. All of the above
Answer : Long Term
34
What is the main purpose of Visual Controls?
a. To show status to upper management
b. To show status to customer
c. To bring out operational problems affecting for early resolution
d. None of the above
Answer : To bring out operational problems affecting for early resolution
35
Which of the following is NOT part of 5 S?
a. SORT
b. Straighten
c. Soften
d. Standardize
Answer : Soften
36
Takt time is a ratio of the ‘Net available time’ to ________________
a. Total Supply
b. Customer demand
c. Both
d. None
Answer : Customer demand
37
Poka Yoke is ______________
a. Mistake Proofing
b. Visual Control
c. Standarization
d. None of above
Answer : Mistake Proofing
38
The “5 Why?” is a ______________ technique
a. 5 S
b. RCA
c. DSM
d. None of the above
Answer : RCA
39
Lean thinking advocates ______________
a. Push Systems
b. Pull Systems
c. both
d. None
Answer : Pull Systems



40
Andon board is an example of ______________
a. Visual Control
b. Dashboard
c. Network diagram
d. None of the above
Answer : Visual Control
41
To reduce test setup change-over time, you considered SMED technique. Which of the following principles can help?
a. Displace
b. Eliminiate
c. Standardize
d. All of the above
Answer : All of the above
42
Customer expects the team to test 10 features in 20 working days. What is the takt time?
a. 10 features/month
b. 2 days/feature
c. 0.5 features/day
d. None of above
Answer : 2 days/feature
43
Which of the following is a part of the Lean philosophy?
a. Management decisions based on a long term perspective
b. Stop when there is a quality problem
c. Leaders going to the actual workplace to see and understand throughly
d. All of the above
Answer : All of the above
44
Following are categories of waste
a. Overproduction
b. Transportation
c. Motion
d. All of the above
Answer : All of the above
45
An effective way to make team memebrs aware of progress made and currents status is through
a. Visual Boards
b. Poka – yoke
c. Mura
d. Muri
Answer : Visual Boards
46
Mistake proofing is
a. Andon
b. Poka – yoke
c. Mura
d. Muri
Answer : Poka – yoke
47
Over production is avoided by using ___________
a. Pull system
b. Poka – yoke
c. Mura
d. Push system
Answer : Pull system
48
How many Lean principles are there according to Jeffrey Liker as presented in “The Toyoto Way”
a. 5
b. 10
c. 14
d. None of the above
Answer : 14
49
How many categories of wastes can be identified as per the Toyota Production System?
a. 7
b. 10
c. 100
d. 20
Answer : 7



50
“Upstream should not produce anything till downstream asks for it” is a part of which Lean principle
a. Poka- yoke
b. DSM
c. Push Mechanismans
d. Pull mechanism
Answer : Pull mechanism
51
The practice in 5S framework by which the work place efficiency is maintained is ________________
a. Sort
b. Shine
c. Sustain
d. All of the above
Answer : Sustain
52
“Pace of production to meet customer demand” is related to _______________
a. Takt Time
b. Talk Time
c. Delay time
d. All of the above
Answer : Takt Time
53
Spending time to finding information can be mapped to _______________ waste
a. Overproduction
b. Inventory
c. Motion
d. All of the above
Answer : Motion
54
A tool in the work area giving the current status of the work
a. Visual Control Board
b. SMED
c. Both 1 and 2
d. None
Answer : Visual Control Board
55
Employing tools to do work otherwise done by people results in reduction of ___________
a. Efforts
b. Schedule
c. Defects
d. 1, 2 and 3
Answer : 1, 2 and 3
56
Automated detection and stopping when a defect occurs is related to ___________
a. Automation
b. Jidoka (autonomation)
c. Genchi Genbutsu
d. Visual Controls
Answer : Jidoka (autonomation)
57
In TPS, high levels of quality is achieved by the principles of
a. Jidoka
b. Poka Yoke
c. Both 1 and 2
d. None
Answer : Both 1 and 2
58
According to Lean thinking, problems should be addressed at
a. Root Cause level
b. Manager level
c. Operator level
d. All the above
Answer : Root Cause level

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59
Kaizen can result in an improvement in _______________
a. Quality
b. Throughput
c. Both 1 and 2
d. None

Answer : Both 1 and 2
60
Problems identified are displayed for everyone’s attention rather than covering up
a. Make the problem visibile
b. Make it fast
c. Make it beautiful
d. None
Answer : Make the problem visibile
61
Any activity that consumes resources, but does not create value is _______________
a. Muda
b. Mura
c. Muri
d. All the above
Answer : Muda
62
Tasks with clear specification on the input, process, time and output are _______________
a. Fixed
b. standardized
c. Designed
d. All the above
Answer : standardized
63
Identification of all activities occuring along the life cycle of the product is _________
a. Value Creation
b. Value Stream Mapping
c. Customer Value
d. None
Answer : Value Stream Mapping
64
Making more parts than you can sell is _______________
a. Overprocessing
b. Overproduction
c. Both 1 and 2
d. None
Answer : Overproduction
65
Optimization of current state map gives the _______________
a. Optimized map
b. Value map
c. Future state map
d. All the above
Answer : Future state map

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66
In the 5 Why analysis, if the root cause is not identified at the 5th Why, one should _______________
a. Stop
b. Start afresh
c. Continue
d. None

Answer : Continue
67
The slowest operation in a process is _______________
a. Work stopper
b. Bottleneck
c. Both 1 and 2
d. None
Answer : Bottleneck
68
What is the ongoing process/philosophy of doing things better, faster and lower cost?
a. Continuous Processs
b. Continuous Engineering
c. Continuous Improvement
d. None
Answer : Continuous Improvement
69
Giving employees more responsibility, authority and accountability for effecting improvements that are within their purview in the daily processes is Employee _______________
a. Empowerment
b. Engagement
c. Endearment
d. None
Answer : Empowerment



70
Lean practices optimizes the
a. Cost
b. Qualitty
c. Schedule
d. All the above
Answer : All the above
71
Achieving predictability of the outcome and making it repeatable is ensured through _______________
a. Concurrent Engineering
b. Predictive Engineering
c. Standardization
d. All the above
Answer : Standardization

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72
Genchi Genbatsu is part of _______________ category in Liker’s 14 principle model
a. Process
b. People and Partners
c. Problem Solving
d. Philosophy

Answer : Problem Solving
73
What is Hansei?
a. Reflection
b. Refraction
c. Retraction
d. Renovation
Answer : Reflection
74
Problems should not remain hidden. They should be _______________ early.
a. Standardized
b. Optimized
c. Surfaced
d. All the above
Answer : Surfaced
75
An engineer fixes a bug request from the customer. The customer value here is _______________
a. Fixed Bug
b. No side effect
c. Both 1 and 2
d. None
Answer : Both 1 and 2
76
Attributes of value deliverables areTimelinessCost
a. Quality
b. Timeliness
c. Cost
d. All the above
Answer : All the above

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77
According to Lean thinking, leaders should work with first hand information from _______________ by direct observation.
a. Customers
b. Workplace
c. Both 1 and 2
d. None

Answer : Workplace
78
Which of the following are examples for Muda?
a. Hand off
b. Task Switching
c. Both 1 and 2
d. None
Answer : Both 1 and 2
79
In a maintenance project with a 3 month release cycle, the team idles during the first six weeks due to lack of clarity. The customer expects team to work as per the planned efforts in the remaining 6 weeks. This will lead to _______________
a. Task switching
b. Overload
c. Poor quality
d. Both 2 and 3
Answer : Both 2 and 3



80
The purpose of VSM is to ____________ and eliminate waste
a. Standardize
b. Empower
c. Identify
d. None
Answer : Identify
81
_______________ is the time taken for those activities that actually transform the product/service in a way that the customer is willing to pay for
a. Takt Time
b. Activity Time
c. Cycle Time
d. Value Added Time
Answer : Value Added Time
82
Those activities that are not mandatory to provide what customer wants are _______________
a. Important
b. Non Value Add
c. Both 1 and 2
d. None
Answer : Non Value Add
83
_______________ is an activity that transforms the input, thereby bringing it closer to the form required by a customer
a. Value Add
b. Muda
c. Muri
d. None
Answer : Value Add
84
Mechanisms (other than inspection at a work place) to achieve in-station quality by prevention is an example of _______________
a. Jidoka
b. Heijunka
c. Poka Yoke
d. All the above
Answer : Poka Yoke

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85
Principles of 5S aim at achieving
a. Efficient work place
b. Jidoka
c. Efficient task switching
d. None

Answer : Efficient work place
86
Standardization helps to reduce variance in
a. Cycle time
b. Quality
c. Both 1 and 2
d. None
Answer : Both 1 and 2
87
Standardized work and environment are the basis for
a. Continuous improvement
b. Defect prevention
c. Both 1 and 2
d. None
Answer : Continous Improvement
88
An operating model with in-station quality is found in
a. Mass production approach
b. Toyota Production System
c. Both 1 and 2
d. None
Answer : Toyota Production System
89
Use of code analysis tools as the code is developed is an example of _______________
a. Concurrent Engineering
b. In station quality
c. first things first
d. None
Answer : In station quality



90
Kaizen is _______________
a. An activity that causes an incidental problem
b. An activity that causes a recurrent problem
c. An activity that enables continuous improvement
d. None of the above
Answer : An activity that enables continuous improvement
91
The 5 Ws of root cause analysis are
a. Who, what, where, when, why
b. What, where, when, who, why
c. Who, who, who, who, who
d. Why, why, why, why, why
Answer : Why, why, why, why, why
92
Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called _______________
a. Heijunka
b. Jidoka
c. Kaizen
d. Kanban
Answer : Jidoka
93
Which of the following are examples of Muda (waste) in the process which should be eliminated?
a. Doing work manually when it can be automated
b. Equipment not working
c. Spending efforts in processing repetitive issues
d. All of the above
Answer : All of the above
94
Lean is _______________
a. Action Oriented
b. Continuous Improvement
c. Process toolkit
d. All of the above
Answer : All of the above

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95
Lean is not _______________
a. Short term gain
b. Problem Solver
c. Action Oriented
d. Continous Improvement

Answer : Short term gain
96
The deciding factors for automation are _______________
a. Feasibility
b. Return of Investment
c. Frequency
d. All the above
Answer : All of the above
97
Understanding the actual situation is known as _______________
a. Capacity Planning
b. Mistake Proofing
c. SS
d. Go and see Yourself
Answer : Go and see Yourself
98
Use _______________ to reduce setup/changeover time
a. SMED
b. 5S
c. RCA
d. VSM
Answer : SMED
99
Issue log or KEDB helps in _______________
a. Mistake proofing
b. Automation
c. VSM
d. Competency management
Answer : Mistake proofing
100
The PM defines the coding standard for a new technology before the development starts. Based on these guidelines, he also reconfigures the code review tool. Choose the Lean tenets PM has applied
a. Standardization & Mistake proofing
b. Standardization & Statistical Analysis
c. Only Standardization
d. 5S and Mistake proofing
Answer : Standardization & Mistake proofing
101
What are the 5 STEPS of 5S?
a. Shine, Solve, Sustain, Sort, Standardize
b. Sustain, Sort, Standardize, Set, Shine
c. Sort, Straighten, Shine, Standardize, Sustain
d. Sort, Sustain, Sushi, Shine, Standardize
Answer : Sort, Straighten, Shine, Standardize, Sustain
102
Which statements defines “VALUE”?
a. The customer has to be willing to pay for the activity
b. The activity must “directly transform” the item or person flowing through the process into what the customer is willing to pay for.
c. The activity must meet all expected requirements on the first attempt
d. All of the above
Answer : All of the above
103
A checklist is a simple example for _______________
a. Mistake proofing
b. Standardization
c. SMED
d. 5S
Answer : Mistake Proofing
104
What is the first step in the VSM?
a. Draw the Value stream mapping(As-IS)
b. Identify the customer Value deliverable
c. Remove the wastes
d. Identify the Value added and Non value added activities
Answer : Identify the customer Value deliverable
105
In a project X, few resources are overburdened due to disparity of competency in teams. This situation is a result of _______________
a. Muda
b. Muri
c. Mura
Answer : Muri
106
Which of the following tenets is used for work place management?
a. SMED
b. 5S
c. VSM
d. DSM
Answer : 5S
107
Which of the following Lean methodologies can be used to identify the waste in the process?
a. DSM
b. 5S
c. VSM
d. CMMI
Answer : VSM
108
Identify the applicable tenet used for identifying the root cause of the problem
a. 5S
b. Statistical Analysis
c. 5WHY
d. PDCA
Answer : 5 WHY
109
In an application maintenance project, the team was following the practice of placing a Red flag in front of the engineer who was stuck up with a problem related to resolving the incident. This is an example of _______________
a. Standardization
b. Kanban
c. Andon
d. None of the above
Answer : Andon
110
How many guiding principles does Lean have?
a. 11
b. 7
c. 12
d. 14
Answer : 14
111
_____________ provides a complete visibility of all work items and status in the team
a. Standardization
b. Mistake Proofing
c. Visual Control
d. ecube
Answer : Visual Control
112
TPS is an integrated socio-technical system, developed by ____________
a. Ford
b. Toyota
c. Wipro
d. IBM
Answer : Toyota
113
Which of the following is not part of 5S?
a. Sort
b. Sustain
c. Shine
d. Sequence
Answer : Sequence
114
According to Womack Lean thinking consists of __________ core principles
a. 3
b. 7
c. 14
d. 5
Answer : 5
115
Which of these are not a core Lean principle according to Womack
a. Pull
b. Flow
c. Value
d. Push
Answer : Push
116
The principle of flow emphasizes on __________
a. reduction in batch size
b. Moving to next phase as quickly as possible
c. Individual productivity
d. Customer satisfaction
Answer : reduction in batch size
117
SMED stands for _____________
a. Single Minute Exchange of Dies
b. Simply More Energy Daily
c. Simplest Most Effective Design
d. Sampling Method for Effort Deviation
Answer : Single Minute Exchange of Dies

 



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