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Question 1. What is the primary purpose of Lean management? A) Increase inventory levels B) Maximize customer value while minimizing waste C) Reduce employee involvement D) Focus solely on cost reduction Answer: B Explanation: Lean’s core objective is to deliver maximum value to the customer by eliminating all forms of waste. Question 2. Which of the following best describes the origin of Lean principles? A) Six Sigma methodology B) Toyota Production System (TPS) C) Theory of Constraints D) Agile software development Answer: B Explanation: Lean evolved from the Toyota Production System, which pioneered waste reduction and continuous improvement. Question 3. In the Five Core Principles of Lean, “Identify Value” refers to: A) Determining the cheapest production method B) Understanding what the customer defines as valuable (VoC) C) Counting the number of defects D) Measuring machine uptime Answer: B Explanation: Value is defined exclusively by the customer’s perspective, known as the Voice of the Customer.
Question 4. Which waste is represented by the “D” in the DOWNTIME acronym? A) Defects B) Delays C) Documentation errors D) Downtime of equipment Answer: A Explanation: “D” stands for Defects, one of the seven classic wastes. Question 5. The eighth waste added to the original seven is: A) Overprocessing B) Non‑utilized talent C) Excess inventory D) Unnecessary motion Answer: B Explanation: The eighth waste highlights the loss of employee skills and creativity when they are not fully utilized. Question 6. Mura refers to: A) Overburden of equipment B) Unevenness or variability in a process C) Defective products D) Excess transportation Answer: B Explanation: Mura means unevenness, causing fluctuations that can lead to waste.
Question 10. Which tool is most appropriate for visualizing material and information flow in a process? A) Control Chart B) Value Stream Map (VSM) C) Pareto Chart D) Scatter Diagram Answer: B Explanation: VSM provides a visual representation of current and future states, highlighting waste. Question 11. In a Kanban system, a “card” is used to: A) Record employee attendance B) Signal the need to produce or replenish inventory C) Document quality defects D) Schedule maintenance activities Answer: B Explanation: Kanban cards act as pull signals that trigger production based on actual consumption. Question 12. The first “S” in the 5S methodology stands for: A. Standardize B. Sort (Seiri) C. Shine (Seiso) D. Sustain (Shitsuke) Answer: B Explanation: Seiri (Sort) involves removing unnecessary items from the workplace.
Question 13. Which of the following is a characteristic of a Kaizen Blitz? A) Duration of several months B) Focus on a single, short‑term improvement project C) No involvement of front‑line workers D) Implementation without any data collection Answer: B Explanation: Kaizen Blitzes are rapid, focused events lasting days to weeks, targeting specific problems. Question 14. The term “Jidoka” is best defined as: A) Continuous flow of materials B) Automation with a human touch that stops when a defect occurs C) Reducing setup time to less than 10 minutes D) Visual management of workstations Answer: B Explanation: Jidoka enables machines to detect abnormalities and stop automatically, ensuring quality at the source. Question 15. Which of the following is NOT one of the Seven Classic Wastes? A) Motion B) Overprocessing C) Standardization D) Waiting Answer: C Explanation: Standardization is a Lean tool, not a waste.
Question 19. Which of the following is a visual control used to alert operators of a problem on the shop floor? A) Andon B) Kaizen C) DMAIC D) Poka‑Yoke Answer: A Explanation: Andon lights or displays signal abnormal conditions, prompting immediate response. Question 20. In the DMAIC framework, the “Analyze” phase focuses on: A) Defining the problem statement B. Measuring current performance C) Identifying root causes of variation D) Controlling the improved process Answer: C Explanation: Analyze uses data to pinpoint the sources of defects or variation. Question 21. Which of the following best describes “One‑Piece Flow”? A) Producing large batches to reduce setup time B) Moving a single unit through each process step without interruption C) Storing inventory at each workstation D) Scheduling production based on forecast demand only Answer: B Explanation: One‑Piece Flow ensures each item progresses continuously, minimizing waiting and inventory.
Question 22. The primary purpose of a Control Chart is to: A) Identify the most frequent defect type B) Monitor process stability over time C) Display the relationship between two variables D) Rank causes of a problem Answer: B Explanation: Control charts show whether a process is in statistical control. Question 23. Which waste is directly addressed by implementing Poka‑Yoke devices? A) Motion B) Defects C) Overproduction D) Waiting Answer: B Explanation: Poka‑Yoke prevents errors from occurring, thereby reducing defects. Question 24. In TPM, “Overall Equipment Effectiveness (OEE)” is calculated as: Availability × Performance × Quality Answer: A (the statement itself is the answer) Explanation: OEE multiplies the three factors to quantify equipment productivity. Question 25. The “M” in “Mura” stands for: A) Motion B) Unevenness (Mura)
C) Reworking defective parts D) Excessive transportation between workstations Answer: B Explanation: NNVA activities do not add value to the product but are required for compliance or safety. Question 29. The “Hoshin Kanri” process is primarily used for: A) Daily housekeeping tasks B) Aligning strategic objectives with operational activities C) Designing equipment layouts D) Conducting root‑cause analysis Answer: B Explanation: Hoshin Kanri (policy deployment) translates long‑term vision into actionable goals. Question 30. Which statistical tool helps visualize the distribution of a single variable? A) Pareto Chart B) Histogram C) Scatter Diagram D) Fishbone Diagram Answer: B Explanation: A histogram shows frequency distribution of data points. Question 31. The “5S” step “Shitsuke” focuses on: A) Sorting items B) Setting items in order C) Sustaining discipline and habits
D) Standardizing procedures Answer: C Explanation: Shitsuke means to maintain and instill the discipline of 5S practices. Question 32. In the context of Lean, “Takt Time” is defined as: A) The time required to complete one unit of work B) The maximum allowable time between customer demands C) The total lead time of a process D) The time a machine is idle Answer: B Explanation: Takt Time equals available production time divided by customer demand, setting the pace for production. Question 33. Which tool is used to prioritize problems based on the 80/20 rule? A) Check Sheet B) Pareto Chart C) Flow Chart D) Control Chart Answer: B Explanation: Pareto analysis identifies the few causes that generate the majority of problems. Question 34. The “Andon” system primarily serves to: A) Schedule preventive maintenance B) Provide real‑time visual alerts of problems on the line C) Track employee attendance
D) Focusing solely on cost reduction Answer: B Explanation: Kaizen respects people while confronting process issues directly. Question 38. Which of the following is a common metric for measuring waste in transportation? A) Number of handoffs per unit B) Cycle time of a machine C) Percentage of defective parts D) Employee overtime hours Answer: A Explanation: Excess transportation is often measured by the number of unnecessary movements or handoffs. Question 39. The “Fishbone Diagram” is also known as: A) Flowchart B) Pareto chart C) Ishikawa diagram D) Control chart Answer: C Explanation: The diagram’s shape resembles a fish’s skeleton and is used for root‑cause analysis. Question 40. Which Lean tool helps convert internal setup steps to external ones during SMED? A) Kanban B) Poka‑Yoke C) External setup conversion
D) 5S
Answer: C (the technique of converting internal to external setups) Explanation: SMED focuses on moving tasks that can be done while equipment runs (external) to reduce downtime. Question 41. The “Voice of the Customer” (VoC) is primarily captured through: A) Machine sensor data B) Employee suggestion boxes C) Direct customer feedback, surveys, and complaints D) Production schedules Answer: C Explanation: VoC reflects customers’ expressed needs and expectations. Question 42. Which of the following best describes “Muri”? A) Uneven workload distribution B) Overburdening of people or equipment C) Defective products D) Unnecessary inventory Answer: B Explanation: Muri is the stress placed on resources due to unevenness (Mura) or waste (Muda). Question 43. In a Pull system, the number of Kanban cards needed is calculated by: (Lead time × Demand) ÷ Container size, adjusted for safety stock. Answer: A (the statement itself is the answer)
Explanation: Batching creates larger inventories between steps, increasing waiting and storage waste. Question 47. In Lean Six Sigma, the “DMEDI” framework is used primarily for: A) Reducing variation in existing processes B) Designing new processes or products C) Conducting root‑cause analysis D) Managing inventory levels Answer: B Explanation: DMEDI (Define, Measure, Explore, Develop, Implement) focuses on process design. Question 48. Which of the following is an example of “Non‑Value‑Added” (NVA) activity? A) Assembling a component required for the final product B) Re‑inspecting a part that already passed quality checks C) Performing a required safety test D) Packaging a finished product for shipment Answer: B Explanation: Re‑inspection adds no value and represents waste. Question 49. The “Six Big Losses” in TPM refer to: A) Six types of employee disengagement B) Six primary causes of equipment downtime C) Six categories of material waste D) Six steps in the Kaizen event Answer: B
Explanation: The Six Big Losses (breakdowns, setup/changeover, small stops, reduced speed, etc.) are major sources of OEE loss. Question 50. Which Lean principle directly addresses “Creating Flow”? A) Establish Pull B) Seek Perfection C) Identify Value D) Create Flow Answer: D Explanation: The principle “Create Flow” mandates arranging value‑adding steps in uninterrupted sequence. Question 51. A “Standard Work Combination Table” is used to: A) List employee skills B) Determine the sequence and timing of tasks for a workstation C) Map material flow across the factory D) Record defect types Answer: B Explanation: It visualizes the blend of manual and machine operations and their timing. Question 52. Which of the following best illustrates “Continuous Improvement”? A) Implementing a one‑time cost‑cutting initiative B) Periodically reviewing processes and making incremental changes C) Outsourcing production to reduce labor costs D) Replacing all equipment every year
Explanation: The 80/20 rule helps focus improvement efforts on the most impactful causes. Question 56. Which of the following is a typical output of a Kaizen event? A) A new corporate vision statement B) Updated Standard Operating Procedures (SOPs) C) A complete redesign of the product line D) A decision to increase overtime permanently Answer: B Explanation: Kaizen events often result in revised SOPs that capture the new best practice. Question 57. In the context of Lean, “Pull” versus “Push” refers to: A) Pull: produce to forecast; Push: produce to actual demand B) Pull: produce based on actual consumption; Push: produce to schedule regardless of demand C) Pull: increase inventory; Push: reduce inventory D) Pull: employee empowerment; Push: management control Answer: B Explanation: Pull aligns production with real demand, whereas Push follows a predetermined schedule. Question 58. Which of the following is an example of “Mura” in a production line? A) Constant, balanced workload across all stations B) Sudden spikes in work volume causing bottlenecks C) Machines operating at full capacity without downtime D) Employees performing multiple tasks simultaneously Answer: B Explanation: Variability in workload creates unevenness (Mura).
Question 59. Which of the following best describes “Visual Factory” concepts? A) Using complex software dashboards only B) Employing visual cues (boards, colors, signs) to convey status instantly C) Relying solely on verbal communication for updates D) Keeping all performance data hidden from operators Answer: B Explanation: Visual management makes information transparent and quickly understandable. Question 60. The “6 Sigma” component of Lean Six Sigma primarily targets: A) Reducing lead time B) Eliminating waste C) Reducing process variation and defects D) Increasing batch sizes Answer: C Explanation: Six Sigma focuses on statistical reduction of defects and variation. Question 61. Which of the following is a typical cause of “Overproduction” waste? A) Accurate demand forecasting B) Producing items before they are needed C) Implementing a pull system D) Reducing setup time Answer: B Explanation: Overproduction creates excess inventory and ties up resources.
