Download GSDC Certified Lean Implementer Certification Exam and more Exams Technology in PDF only on Docsity!
Exam
Question 1. Which of the following best defines “value” in Lean terminology? A) Any activity that adds cost to the product B) Any activity that the customer is willing to pay for C) Any activity that reduces cycle time D) Any activity that eliminates waste Answer: B Explanation: In Lean, value is defined from the customer’s perspective as what the customer is willing to pay for; all other activities are considered non‑value‑added. Question 2. The first principle of Lean is to “Define value.” Which tool is most commonly used to capture the customer’s definition of value? A) Value Stream Map B) Voice of the Customer (VOC) C) Spaghetti Diagram D) 5 Whys Answer: B Explanation: VOC gathers direct input from customers about what they consider valuable, forming the basis for defining value. Question 3. In the Five Principles of Lean, which step directly follows “Identifying the Value Stream”? A) Establish Pull B) Create Flow C) Seek Perfection
Exam
D) Define Value Answer: B Explanation: After mapping the value stream, the next step is to create continuous flow by eliminating interruptions. Question 4. Which of the following is NOT one of the DOWNTIME wastes? A) Defects B) Overproduction C) Motion D) Utilization Answer: D Explanation: Utilization is not a waste; the eight wastes are Defects, Overproduction, Waiting, Non‑utilized talent, Transportation, Inventory, Motion, and Extra‑processing. Question 5. A manufacturing line frequently stops because operators must wait for parts from the previous station. Which waste does this represent? A) Overproduction B) Waiting C) Motion D) Inventory Answer: B Explanation: Waiting waste occurs when people or equipment are idle due to lack of material, information, or equipment.
Exam
D) Lead time of the process Answer: B Explanation: Takt time equals available production time divided by customer demand; it synchronizes production with demand. Question 9. When creating a current state Value Stream Map, which data point is NOT typically collected? A) Cycle time of each operation B) Changeover time between products C) Employee satisfaction score D) Number of operators at each workstation Answer: C Explanation: While valuable, employee satisfaction is not a standard VSM data point; VSM focuses on process times, inventories, and resources. Question 10. A “bottleneck” in a value stream is best described as: A) The operation with the highest defect rate B) The step with the longest lead time relative to demand C) The workstation with the most inventory in front of it D) The activity that adds the most value Answer: B Explanation: A bottleneck limits overall flow because its capacity is less than the demand placed on it, often reflected by a long lead time.
Exam
Question 11. In future state design, a “supermarket” pull system is used to: A) Store excess inventory for emergencies B) Signal downstream demand to upstream processes via visual cues C) Increase batch sizes for efficiency D) Replace kanban cards with electronic sensors Answer: B Explanation: A supermarket is a controlled inventory point that triggers replenishment based on actual consumption, supporting pull. Question 12. Which of the following criteria is most important when prioritizing Kaizen events after a VSM analysis? A) The event’s popularity among staff B) The potential reduction in lead time or waste C) The availability of external consultants D) The number of tools required Answer: B Explanation: Kaizen events are prioritized based on their expected impact on waste reduction and lead‑time improvement. Question 13. The first “S” in the 5S system stands for “Sort.” What is the primary objective of Sort? A) Arrange tools in order of use B) Remove unnecessary items from the work area
Exam
Explanation: Quality Control Circles are not a TPM pillar; the eight pillars include Autonomous Maintenance, Planned Maintenance, Focused Improvement, etc. Question 16. Overall Equipment Effectiveness (OEE) is calculated by multiplying: A) Availability, Performance, and Quality B) Utilization, Yield, and Cycle Time C) Capacity, Efficiency, and Downtime D) Throughput, Lead Time, and Scrap Rate Answer: A Explanation: OEE = Availability × Performance × Quality, providing a comprehensive equipment efficiency metric. Question 17. Which statement best describes “Standardized Work”? A) A flexible set of instructions that changes daily B) The best known method for performing a task, documented and repeatable C) A set of visual cues used only for safety D) A process that eliminates all human involvement Answer: B Explanation: Standardized work captures the current best practice to ensure consistency and provide a baseline for improvement. Question 18. When balancing a work cell using takt time, the number of operators required at a workstation is calculated by: A) Cycle time ÷ takt time
Exam
B) Takt time ÷ cycle time C) Lead time ÷ takt time D) Changeover time ÷ takt time Answer: A Explanation: Operators needed = Cycle Time ÷ Takt Time; if the result is >1, multiple workers are required. Question 19. In a pull system, the primary purpose of a Kanban card is to: A) Record employee attendance B) Signal the need to produce or move a specific quantity of items C) Track machine maintenance schedules D) Document quality inspection results Answer: B Explanation: Kanban cards convey demand downstream and trigger upstream production or replenishment. Question 20. For a two‑card Kanban system, the “withdrawal” card is used to: A) Request raw materials from suppliers B) Signal the need to move finished goods to the next process C) Authorize equipment shutdowns D) Indicate a quality defect Answer: B
Exam
C) Amount of inventory held on the floor D) Time spent on quality inspections Answer: A Explanation: U‑shaped cells reduce movement and transportation by placing all required processes within a compact loop. Question 24. Cross‑training workers in a cellular environment is essential because: A) It allows workers to operate any machine in the cell, increasing flexibility B) It reduces the need for safety equipment C) It eliminates the need for standard work D) It increases the number of kanban cards required Answer: A Explanation: Cross‑training enables workers to perform multiple tasks, supporting flow and reducing bottlenecks when absences occur. Question 25. Poka‑Yoke devices are designed to: A) Increase the speed of a production line B) Prevent errors by making it difficult to perform a mistake C) Reduce the number of operators needed D) Automate the entire process Answer: B Explanation: Error‑proofing (poka‑yoke) mechanisms detect or prevent mistakes before they result in defects.
Exam
Question 26. An Andon system typically includes: A) A kanban board and a Gantt chart B) Visual and audible alerts that indicate a problem at a workstation C) A statistical process control chart only D) A set of standard operating procedures Answer: B Explanation: Andon alerts (lights, sounds) notify supervisors and team members of abnormal conditions, prompting immediate response. Question 27. The “5 Whys” technique is used to: A) Determine the root cause of a problem by repeatedly asking “Why?” B) Rank waste types by severity C) Calculate takt time for a process D) Develop a future state value stream map Answer: A Explanation: By asking “Why?” five times (or as needed), the technique drills down to the underlying cause of an issue. Question 28. In a Fishbone (Ishikawa) diagram, which category would “Machine Calibration” belong to? A) Methods B) Materials C. Machines
Exam
Question 31. In the context of Lean, “non‑utilized talent” refers to: A) Employees who are not trained in Lean tools B) Workers whose skills are not fully engaged in value‑adding activities C) Overstaffed production lines D) Outsourced functions Answer: B Explanation: Non‑utilized talent is a waste where human capabilities are underused, such as employees performing repetitive, low‑skill tasks. Question 32. Which of the following is a key benefit of implementing a pull system? A) Higher inventory levels to buffer demand fluctuations B) Production based on forecast rather than actual demand C) Reduced lead times and inventory through production only when needed D) Increased reliance on long changeover times Answer: C Explanation: Pull systems produce only what is needed when it is needed, minimizing inventory and lead time. Question 33. The term “lead time” refers to: A) The time a machine is operating at full capacity B) The total elapsed time from order receipt to product shipment C) The time required to set up a machine for a new batch D) The time spent on quality inspections
Exam
Answer: B Explanation: Lead time encompasses the entire process from customer order to delivery. Question 34. When calculating the number of Kanban cards required for a part, which formula is commonly used? A) (Demand per day × Lead time) ÷ Container size B) (Takt time × Cycle time) ÷ Number of operators C) (Inventory × Defect rate) ÷ Changeover time D) (Availability × Performance) ÷ Quality Answer: A Explanation: Kanban quantity = (Demand × Lead time) ÷ Container size, often adjusted for safety stock. Question 35. In SMED, “internal” setup activities are those that: A) Can be performed while the machine is running B) Must be done when the machine is stopped C) Require external suppliers to be present D) Are related to quality inspection Answer: B Explanation: Internal setups require the equipment to be offline; converting them to external tasks reduces downtime. Question 36. Which of the following is a primary goal of cellular manufacturing? A) Increase the number of workstations in a line
Exam
Question 39. Which metric is most directly improved by implementing Autonomous Maintenance? A) Cycle time B) Overall Equipment Effectiveness (OEE) C) Lead time D) Takt time Answer: B Explanation: Autonomous Maintenance engages operators in routine upkeep, directly boosting OEE by reducing breakdowns and defects. Question 40. In the context of Lean, “flow” is best described as: A) The speed at which inventory moves through the warehouse B) The uninterrupted movement of products or information through a process C) The number of kanban cards circulating in a system D) The amount of overtime required to meet demand Answer: B Explanation: Flow means work proceeds smoothly without stops, delays, or bottlenecks. Question 41. Which of the following is a typical characteristic of a “future state” value stream map? A) Inclusion of all current waste items B) Depiction of a perfectly balanced line with zero inventory C) Representation of current lead times and bottlenecks
Exam
D) Use of historical demand data only Answer: B Explanation: Future state maps illustrate an ideal, waste‑free flow with minimal inventory and balanced resources. Question 42. The “Pull” principle in Lean is most closely associated with which scheduling concept? A) Push scheduling based on forecast B) Kanban‑driven replenishment based on actual consumption C) Fixed‑date production planning D) Batch‑size maximization Answer: B Explanation: Pull uses kanban signals to produce only what is needed, aligning production with real demand. Question 43. Which of the following best illustrates “Extra‑processing” waste? A) Machining a part to tighter tolerances than the customer requires B) Storing raw materials in a distant warehouse C) Waiting for a supervisor’s approval before starting work D) Using a manual crane to move a pallet Answer: A Explanation: Extra‑processing adds unnecessary steps or higher specifications beyond what the customer values.
Exam
Answer: B Explanation: A spaghetti diagram maps the actual routes taken, highlighting unnecessary motion. Question 47. In a Kanban system, “safety stock” is typically added to the calculation to: A) Increase the number of kanban cards beyond demand B) Compensate for variability in demand or lead time C) Reduce the need for visual controls D) Eliminate the need for changeover reduction Answer: B Explanation: Safety stock buffers against fluctuations, ensuring the pull system does not starve. Question 48. Which of the following statements about “Standard Work Combination Table” is true? A) It is used to calculate OEE B) It shows the sequence and timing of tasks for a worker in a cell C) It replaces the need for a value stream map D) It is only applicable to service industries Answer: B Explanation: The combination table documents the order and duration of tasks, enabling balanced work distribution. Question 49. The primary purpose of “Visual Management” in Lean is to:
Exam
A) Reduce the need for training B) Make the status of the process instantly understandable to all C) Increase the number of paperwork required D) Replace all numeric performance metrics Answer: B Explanation: Visual cues (boards, signs, colors) provide immediate insight into performance and problems. Question 50. In a “two‑bin” inventory system, when the first bin is empty, the action taken is: A) Shut down the line until the bin is refilled B) Pull the second bin forward and request replenishment for the empty bin C) Increase production speed to compensate D) Perform a quality inspection on the remaining items Answer: B Explanation: The empty first bin triggers a replenishment request while the second bin supplies the demand. Question 51. Which of the following is an example of “Non‑value‑added motion”? A) Walking to retrieve a tool that is stored far from the workstation B) Operating a machine at its optimal speed C) Conducting a required inspection D) Using a standardized work instruction
