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1. The various kinds of Kanban include:
  1. Supplier Kanban
  2. In-Factory Kanban
  3. Customer Kanban
  4. In-House Kanban
  5. All of the above
2. What are the three C’s essential for Supply Chain Management?
  1. Cooperation
  2. Communication
  3. Coordination
  4. Customer Satisfaction
3. Why did Ford begin to lose its hold in the market?
  1. There were clashes between the laborers and the Ford system
  2. There was a sudden rise in the product variety
  3. Annual changes in models and multiple colors and options suited the Ford factories
  4. All of the above
4. Which of the following is necessary for the success of Lean implementation?
  1. There needs to be a total cultural change in the organization
  2. The command-and-control approach needs to be imbibed
  3. The people have to be downsized
  4. The value stream has to be mapped
  5. The senior mangement need not be active participants in the Lean implementation program
5. Which of the following are true regarding value stream mapping?
  1. It is a tool to look at how value flows into and through a process to the customer
  2. It cannot be applied to service processes because the value stream cannot be traced in these processes
  3. It helps to locate the wastes in the value chain
  4. It cannot be used to map information flows
6. Which principle of Lean makes use of spaghetti charts?
  1. Value
  2. Flow
  3. Value Stream
  4. Pull
7. Where was the first TPM conference held?
  1. Canada
  2. Japan
  3. The United Kingdom
  4. The United States
8. Pull System is another name for ______.
  1. Poka-Yoke
  2. Kanban
  3. Standard Work
  4. SMED
9. Which method helps in the optimization of machinery?
  1. FMEA
  2. Total Productive Maintenance
  3. Kanban
  4. Cycle Time Reduction
10. Cycle Time Reduction is:
  1. the time needed to complete a task within a process
  2. the time needed to manufacture a product
  3. the time needed to design a product
  4. the time needed to deliver a product to the customer
11. State whether true or false:
Applying Lean to Supply Chain Management helps to certify the suppliers.
  1. True
  2. False
12. Which of these need not be a feature of Lean metrics?
  1. They are fundamental for decision-making purposes
  2. Building a Lean enterprise is an important basis for good metrics
  3. They should be made keeping in mind the goals of the competitor
  4. They should be simple to understand and presented in a clear manner
13. Which of the following losses does not eliminate TPM?
  1. Breakdown losses
  2. Production losses
  3. Speed losses
  4. Quality losses
14. What is the main reason for the occurrence of waste?
  1. Single Unit Processing
  2. Inventory
  3. Cycle Time
  4. Lean Manufacturing
15. Which of the following is not done by poka-yoke?
  1. It easily recognizes flaws in a product and thwarts the manufacturing of incorrect parts
  2. It signals and specifies a trait in a product or a process
  3. It helps in the optimization of resources in an organization
  4. It is the first step in proofing a system
16. What is the function of SMED?
  1. To increase output and quality losses
  2. To reduce the changeover in a process
  3. To improve supplier relations
  4. All of the above
17. Who is known as the “father of scientific management”?
  1. Henry Ford
  2. Shigeo Shingo
  3. Frank Gilbreth
  4. Frederick Winslow Taylor
18. Whom did the four locations on the large board of the Beer Game not represent?
  1. The Factory
  2. The Distributor
  3. The Customer
  4. The Wholesaler
19. Which of the following is not a Lean Tool?
  1. Standardization
  2. 5s-Cando
  3. Kanban
  4. Design of Experiments
20. Which of the following cannot be considered a waste?
  1. Waiting time
  2. Overproduction
  3. Skilled plant workers
  4. Long process setup
21. What is the formula to calculate cycle time?
  1. [Inventory (units)] / [Demand (units/time)]
  2. Available work time / Customer required volume
  3. Customer required volume / Available work time
  4. None of the above
22. What does Kanban mean?
  1. A card-signal
  2. A go ahead signal
  3. A warning-signal
  4. None of the above
23. For any company to reach a ‘level 6’ sigma, there should only be _______ defects per million opportunities.
  1. 1
  2. 2.2
  3. zero
  4. 3.4
24. What is the similarity between Lean and Six Sigma?
  1. Both view waste as anything that does not produce value
  2. Both focus on process flow
  3. Both deliver higher quality of service with greater speed
  4. None of the above
25. Synchronous Flow Manufacturing plans inventory around:
  1. Capacity Enhancing Resources
  2. Capacity Defining Resources
  3. Capacity Constraint Resources
  4. capacity Cutting resources
26. The data that does not need to be communicated in a Visual Factory environment are:
  1. process metrics
  2. the name of the employees
  3. work instructions
  4. general plant information
27. What is also known as ‘law zero’ in Lean Six Sigma?
  1. The Law of Waste
  2. The Law of the Market
  3. The Law of Focus
  4. The Law of Competition
28. Which of the following is not synonymous with Lean Manufacturing?
  1. World Class Manufacturing
  2. Wasteless Manufacturing
  3. Continuous Flow Manufacturing
  4. Stockless Production
29. Who introduced the concept of mass production?
  1. Frank Gilbreth
  2. Henry Ford
  3. Benjamin Franklin
  4. Frederick Winslow Taylor
30. What is Takt Time?
  1. The time required to manufacture a product
  2. The consideration of customer demands and the time of the demands
  3. The time between the order and the delivery of the product
  4. None of the above
31. Which of the following is true with regard to Synchronized Flow Manufacturing?
  1. It means coordination between plant workers and management
  2. It means processes and related decisions in the management must be synchronous with each other
  3. It improves the manufacturing system by setting off an increase in operating costs
  4. It means that all parts of the system must be continuous and in harmony with each other to avoid inventory pileups and stoppages.
32. A flexible process is:
  1. an expensive and time consuming process because it requires change of equipment and tools for different customer demands
  2. one which can be reconfigured to give different output for different customer demands
  3. a ‘push’ system
  4. one that generates a level and consistent schedule
33. Which of these features does not describe the features of the Ford system?
  1. Materials do not go from “dock to stock” but from dock to the factory floor
  2. Inventory binds capital and getting rid of inventory frees capital
  3. Pull system
  4. Reducing the cycle time also frees capital
34. Who among the following is involved in the implementation of Kaizen?
  1. Top Management
  2. Suppliers
  3. Workers
  4. Customers
35. How many wastes are identified by Lean?
  1. Only 1
  2. 10
  3. 8
  4. 100
36. What is not an advantage of SMED?
  1. It helps to achieve consistency in the process
  2. It helps in continuous improvement of the process
  3. It increases elasticity in the process
  4. It is a measure of performance
37. Six Sigma processes are implemented by organizations to reduce __________.
  1. defects in their processes
  2. costs of poor quality
  3. infrastructure defects
  4. process improvements
  5. employees
38. What is the main function of Lean?
  1. Eliminating muda
  2. Increasing cycle time
  3. Downsizing personnel
  4. Improving process capability
39. According to the Theory of Constraints, ______________________.
  1. every process or system has a constraint that acts as an impediment in attaining less of its goal
  2. the manufacturing process is enhanced by its capacity constraint resource
  3. every process or system has a constraint that acts as an impediment in attaining more of its goal
  4. time lost at a constraint can be gained back
40. _________ means to clear the work area.
  1. Sort
  2. Set in Order
  3. Shine
  4. Standardize
41. What are the advantages of applying Lean to a supply chain?
  1. It helps speed up the expansion and execution operations
  2. It turns the organization into a major customer of all the suppliers they have dealt with
  3. It helps to decrease the number of variables with which the production, quality and dependability has to cope with
  4. All of the above
  5. None of the above
42. State whether true or false:
Single unit manufacturing cannot be approximated to continuous flow manufacturing.
  1. True
  2. False

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