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Lean Quiz
Test Your Knowledge of Lean Thinking

1. Lean manufacturing is a: a) Method for reducing labor cost
b) Means to improve responsiveness to the customer
c) Efficiency improvement technique
d) Set of tools designed to improve productivity

2. Which of the following is not a goal of lean manufacturing? a) Reducing set-up times
b) Utilizing activity-based costing
c) Increasing machine utilization
d) Producing smaller lot sizes

3. Which of the following is not one of the eight wastes? a) Overproduction
b) Transporting
c) Excess machine capacity
d) Waiting

4. In a lean workcell, the supervisor’s main responsibility is: a) Keeping production moving
b) Keeping workers busy
c) Achieving production counts
d) Identifying and resolving abnormal conditions

5. Lean Thinking should only be implemented when there is no crisis! a) True
b) False

6. The purpose of set up reduction activity is to: a) Run smaller lot sizes
b) Make more parts
c) Reduce the number of setup personnel
d) Increase productivity

7. Pilot lean projects should be chosen based on: a) Impact to the customer and to the company
b) Anticipated chance for success
c) The number of people affected by the changes
d) All of the above

8. Products with low demand should be: a) Produced in the quantity needed
b) Batch processed and held in stock until needed
c) Assigned higher cost per unit
d) Discontinued or purchased from another supplier

9. Kanban is based on a model of: a) Shipyards
b) Automotive assembly lines
c) Supermarkets
d) Job shop machining

10. In a cell, the operators are responsible to: a) Maximize production output
b) Meet customer requirements
c) Run the machines or processes assigned
d) Direct requests to the supervisor

11. Defective product should be: a) Immediately moved to the quality holding area
b) Moved to the rework process
c) Scrapped or repaired immediately.
d) Displayed for everyone to see

12. Set up reduction involves all of the following except: a) Defining internal and external tasks
b) Mistake proofing setup activities
c) Adding adjustments to fixtures and tools
d) Keeping tools and gages in kits

13. Production line problems should be apparent to even a casual observer. a) True
b) False

14. In a manufacturing cell, who has authority to stop production? a) The line supervisor
b) Machine operators
c) The material handler
d) All of the above

15. Top management needs to be included in pilot cells projects. a) True
b) False

16. 5S: a) Is a simple five step process
b) Can be done without managerial support
c) Targets improvements in morale and efficiency
d) Relies on the organization and demarcation of the working areas
e) A and D
f) A, C, and D

17. Place the 5s’s in the proper order: a) Sort, Set-in-order, Shine, Sustain, Standardize
b) Shine, Sort, Standardize, Set-in-order, Sustain
c) Sort, Set-in-order, Shine, Standardize, Sustain
d) Sustain, Set-in-order, Shine, Sort, Standardize
e) Sort, Set-in-order, Standardize, Shine, Sustain
f) Sustain, Standardize, Set-in-order, Shine, Sort

18. Using kanban, production demand is triggered by: a) The production planner
b) Forecast
c) Removal of product by the downstream customer
d) Any of the above

19. Change over should be organized on the basis of: a) The cost of direct vs. indirect labor
b) How many workers it takes to make the change
c) Internal, external, and adjustment
d) Machine utilization

20. “Queue” means: a) A signal to start production
b) A unit of measure
c) Material should be pushed to the next operation when a batch is complete
d) Waiting

21. The main objective of lean manufacturing is to: a) Keep labor costs as low as possible by using more of other resources
b) Produce products with fewer options to simplify consumer choices
c) Produce goods using less resources compared to mass production techniques
d) Outsource much of our manufacturing in order to focus on final assembly

22. We can best increase output by producing parts faster: a) True
b) False

23. One-piece-flow means a) Batch
b) Larger lot sizes
c) One piece moves to the next operation
d) Operators need to work harder

24. The $10,000,000,000 spent on material handling equipment has been to a waste of money. a) True
b) False

25. It takes two to three years to complete Lean Manufacturing implementation. a) True
b) False

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