Q1. Which one of these item is not a type of standard set of waste ?

a) Over production

b) Taxes

c) Transportation

Q 2. What item listed below could be used as preconditions for Kanban ?

a) 100% quality is mandatory

b) 5S: workplace organization

c) Machines operate correctly when they are needed

Q3.  What type of waste is Creating extra reports that no one needs ?

a) Defect

b) Inventory

c) Over Production

Q4.  What are the key metrics tracked in OEE ?

a) Loading, Availability, Performance & Quality

b) Security, performance

c) OEM metrics

Q5.  At which Lean maturity level you can expect Well Defined Process to Follow Lean Principles ?

a) Level 01

b) Level 02

c) Level 03

Q 6.  How would one calculate "Days in Inventory" metrics ?

a) Days in Inventory = Avg Inventory / (COGS / Days)

b) In how many days will the item gets expired?

c) Inventory / Days

Q7.  How is First Pass Yield (FPY) Calculated ?

a) FPY = (Output in First Pass) / (Total Output)

b) FPY = (Defect-Free Output in First Pass) / (Total Input)

c) FPY = (Defect-Free Output) / (Total Pass)

Explanations:Correct answer B. The First Pass Yield (FPY) is Calculated as FPY = (Defect-Free Output in First
Pass) / (Total Input). Any defect fixed in subsequent pass is not counted here.

Q8. What is Lean philosophy?

a) Provide perfect value to the customer through a perfect value creation process that has zero waste

b) Higher output by encouraging people to work hard and have targets

c) Reducing Cost and improving purchasing power for the individuals

Explanations:Correct Answer A. Lean philosophy is to provide perfect value to the customer through a perfect value
creation process that has zero waste. While cost reduction is not the main focus on Lean, this approach helps in cost
reduction as well.

Q9.  Just-In-Time Production methodology was introduced by?

a) Ford

b) Toyota

c) Lean Association

Explanations:Correct Answer A: Just-in-time manufacturing was a concept introduced by Ford

Q10.  Define "wrong use of metrics" type of waste.

a) Wrong person using the Metrics leading to waste of time

b) Any Metrics that is incorrectly measured, incorrectly used, misinterpreted or mis-used

c) Metrics causing change in process

Explanations:Correct Answer B. The definition of waste due to wrong use of Metrics is: Any Metrics that is
incorrectly measured, incorrectly used, misinterpreted or mis-used is another type of waste called "wrong use of
metrics"

Q11. What are the main seven types of waste?

a) Money, Software, Entertainment, Waiting, Resources, Under-utilized machines, Excess machine

capacity

b) Inventory, Storage, Misalignment, Over heating, Electricity, Chatting, Communication

c) Transportation, Inventory, Motion, Waiting, Over-production, Over-processing, Defects

 Explanations:Correct Answer C. The original main 7 types of waste are Transportation, Inventory, Motion,
Waiting, Over-production, Over-processing, Defects. Over a period of time people have added some more types, but
the original seven are not modified.

Q12. Japanese 5S methodology is created and used for?

a) Continuous Improvement

b) Prevent Defects

c) Creating a productive work environment

Explanations:Correct Answer C. Japanese 5s methodology was created and used for organizing, cleaning, developing,
and sustaining a productive work environment

Q13. Which of the 5S technique requires you to separate necessary and unnecessary items at the workplace?

a) Seiri (Sort)

b) Seiton (Stabalize)

c) Non-Value Add

Explanations:Correct Answer A. Seiri (Sort), is the first step in making things cleaned up, sorted, and organized. It
starts out by sorting the necessary and the unnecessary items and remove the unnecessary items from the workplace

Q14. While implementing 5S, red color tags are used to mark items for what reason?

a) Identify important items in a process during design

b) Differentiate between good and defective products from assembly line

c) Differentiate between necessary and unnecessary items in the work place

Explanations:Correct Answer C. The 5S methodology starts by sorting the necessary and the unnecessary. All the
items that are not used frequently and those that are unnessary are marked by red tags so that it can be visually
identified and removed.

Q15. What is significance of the Seiso (Shine) phase of 5S methodology?

a) To ensure the product packaging is good for selling

b) Have clean workspace

c) Removing all the defects

Explanations:Correct Answer B. The third stage of 5S is Seiso, called as Shine in English. In this stage, everything is
kept clean and swept. Working in a clean environment enables workers to notice malfunctions in equipment such as
leaks, vibrations, breakages, and misalignments.

Q16. What does Seiketsu (Standardize) of 5S methodology focuses on?

a) Use of process standardization

b) Adopting Industry Standards

c) Removing all the defects

Explanations:Correct Answer C. Once the first three S of the 5Ss have been implemented, the next pillar is to
standardize the best practices in the work area. Seiketsu called as Standardize in English, is the method to maintain
the first three pillars. It creates a consistent approach with which tasks and procedures are done.

Q17. What part of 5S promotes that all work stations for a particular job should be identical?

a) Seiketsu (Standardize)

b) Seiso (Shine)

c) Seiri (Sort)

Explanations:Correct Answer A. Seiketsu (Standardize) is the right answer. All work stations for a particular job
should be identical. All employees doing the same job should be able to work in any station with the same tools that
are in the same location in every station.

Q18. What tool helps in visualize series of causes to an effect?

a) Ishikawa Diagram

b) Six Sigma

c) Value Stream Mapping

Explanations:Correct Answer A. There are normally a series of root causes stemming from one problem, and they can
be visualized in cause and effect manner using Cause-and-Effect diagram. This was developed by Ishikawa and also
called as Ishikawa diagram.

Q19. Which is the tool or technique used for rapid improvement for discrete process issues?

a) Kanban

b) Kaizen Blitz

c) Kaizen
Explanations:Correct Answer B. The correct answer is Kaizen Blitz (or as it is also called, kaikaku in Japanese). It is a
rapid improvement workshop designed to produce results/approaches to discrete process issues within a few days.

Q20. What is Takt Time?

a) Time taken to create a unit

b) Throughput time

c) Average customer demand time for an article.

Explanations:Correct Answer C. Lean production uses takt time as the rate at which a completed product needs to be
finished in order to meet customer demand.

Q21. What is the name of the process, tool or technique which help in automatic detection of process malfunction and
product defect and prevents it from moving forward in the production process?

a) Kanban

b) Jidoka (Autonomation)

c) Poka Yoke

Explanations:Correct Answer B. Jidoka is a Japanese term used for autonomation means "intelligent automation" or
"humanized automation." In practice, it means that an automated process is sufficiently "aware" of itself so that it will
detect when the desired quality is produced, detect process malfunctions, detect product defects, stop itself and alert
the operator. A future goal of autonomation is selfcorrection.

Q22. Which of these tools / techniques represents "continuous improvement."?

a) Kaizen

b) Six Sigma

c) Kanban

Explanations:Correct Answer A. The word kaizen means "continuous improvement." It is a system of continuous
improvement in quality, technology, processes, company culture, productivity, safety, and leadership. It comes from
the Japanese words ("kai") which means "change" or "to correct" and ("zen") which means "good."

Q23. Plan Do Check Act (PDCA Cycle) was popularized by:

a) Ishikawa

b) Kaizen

c) Deming

Explanations:Correct Answer C. PDCA was made popular by Dr W. Edwards Deming, who is considered by many to
be the father of modern quality control.
Q24. The "5 Whys" technique is used for what purpose?

a) Continuous Improvement

b) Reduce Waste from a process

c) Find out root cause of a problem

Explanations:Correct Answer C. Five (5) Whys, is a form of root cause analysis in which the user asks "why" to a
problem and finds an answer five successive times. There are normally a series of root causes stemming from one
problem.

Q25. SMED stands for?

a) Single-Minute Exchange of Die

b) Standard Material Engineering and Deployment

c) Social Media Exchanged Devices

Explanations:Correct Answer A. SMED is the term used to represent the Single-Minute Exchange of Die or setup
time that can be counted in a single digit of minutes. SMED is often used interchangeably with quick changeover.

Q26. For many people, changing a single tire can easily take 15 minutes. But, for a NASCAR pit crew, changing four
tires takes less than 15 seconds. This represent good use of what tool?

a) SMED (Single-Minute Exchange of Die)

b) Kanban

c) Six Sigma

Explanations:Correct Answer A. The successful implementation of SMED and quick changeover is the key to a
competitive advantage for any Process

Q27. What are five phases of 5S?

a) Shine, Shut-Up, Sustain, Sort, Standardize

b) Sustain, Sort, Standardize, Sushi, Shine

c) Sort, Set-in-Order, Shine, Standardize, Sustain

Explanations:Correct Answer C. The five steps in 5S are Sort, Set-in-Order, Shine, Standardize & Sustain.

Q28. What does PDCA stands for?

a) Process Delegating Control Automation

 b) Plan Do Check Act

c) Prepare, Deliver, Check and Act

Explanations:Correct Answer B. PDCA stands for Plan Do Check Act is the correct.

Q29. Taiichi Ohno developed Kanban based on which model?

a) Call Center

b) Supermarkets

c) Toyota Manufacturing

Explanations:Correct Answer B. Taiichi Ohno was inspired by the American supermarket's working and applied to
auto industry. The technique is called Kanban that means Signboard

Q30. single-piece flow, pull production" was achieved using which method?

a) Lean Manufacturing

b) Six Sigma

c) Re-Engineering

Explanations:Correct Answer A. Lean manufacturing represents a fundamental paradigm shift from traditional batch
and queue mass production to production systems based on product aligned single-piece flow, pull production.

Q31. In which year Boeing implemented Lean

a) Year 1971

b) Year 2000

c) Year 1996

Explanations:Correct Answer C. The Boeing Company began implementing Lean manufacturing throughout its
Commercial Airplanes division in February 1996.

Q32. In healthcare service industry "excess amount of blood drawn" is what type of waste?

a) OverProduction

b) Defect

c) Inventory

Explanations:Correct Answer A. Any access blood drawn than necessary is overproduction.

Q33. What type of waste is "nurse transporting patients to x-ray room"?

a) OverProduction

b) Motion

c) Under-utilization

Explanations:Correct Answer C. When people are doing some work that could be done by lower skill people, it would
fall into this type of waste. An example would be a nurse transporting patients to x-ray room; this could very well be
done by ward-boy or assistants.

Q34. What type of waste is Patients waiting to be seen by the doctors?

a) Waiting

b) Over production

c) Under-utilization

Explanations:Correct Answer A. Patients waiting for doctor to be seen is waiting type of waste. If the doctor is
waiting for patients then it would be underutilization.

Q35. What type of waste is "insufficient quantity or overdose of medicine is given to the patient"?

a) Over Production

b) Defect

c) Under-utilization

Explanations:Correct Answer B. The severity of this waste can be fatal if the work is not done right the first time. If
an incorrect medicine, insufficient quantity or overdose of medicine is given to the patient, it will be an critical defect
type of waste - which might lead to fatal injury/death or retreatment, etc.

Q36. What type of waste is "Purchasing and storing office supply, sales literature, etc."?

a) Over Production

b) Inventory

c) Motion

Explanations:Correct Answer B. Any access purchase and storage of office supply, sales literature, Reports, etc.
would constitute inventory type of waste.

Q37. What type of waste is "Excessive or unnecessary emails and document get forwarded multiple times"?
 a) Over Production

b) Inventory

c) Extra Motion

Explanations:Correct Answer C. The Waste type is "Extra Motion". If excessive or unnecessary emails and document
get forwarded multiple times sometimes with large attachments due to multiple distribution groups, it constitutes
waste of type motion.

Q38. What is an appropriate Lean metric to capture effective utilization of manufacturing operation in a factory?

a) Overall Equipment Effectiveness (OEE)

b) Efficiency

c) Six Sigma

Explanations:Correct Answer A. Overall equipment effectiveness (OEE) is a hierarchy of metrics which evaluates and
indicates how effectively a manufacturing operation is utilized.

Q39. How can one provide assessment of financial, behavioral, and core process performances on an on-going basis
to track continuous improvement efforts of the company?

a) Using Lean Metrics

b) Using Six Sigma

c) Regular Status Reports

Explanations:Correct Answer A. Lean metrics are established to allow a company to measure, evaluate, and respond
to their overall performance across all dimensions. Often, these metrics are a means to discover Lean performance
indicators that tell the tale of continuous improvements and Lean implementation effectiveness.

Q40. What metrics capture availability, performance, and quality components of a manufacturing unit?

a) Quality of Service

b) Overall equipment effectiveness

c) Total effective equipment performance

Explanations:Correct Answer B. Overall Equipment Effectiveness (OEE) breaks the performance of a manufacturing
unit into three separate but measurable components: availability, performance, and quality.