Learning to See

Lean Manufacturing Exam

NAME: _______________________________________
EXAM DATE: ______/______/______
For the following multiple choice questions, please indicate the best answer. Some
answers may be correct but incomplete and not the best answer. Every correct
response will earn the examine a point. Question 6, 8, 11, 13, 15, 16, 24, 27, 29, 30
and 31 are worth multiple points for correct responses. A calculator might be
required.
1. Value Stream Mapping looks at:
A.
B.
C.
D.

The
The
The
The

people, material, and information flow in a value stream.

material and information flows in a value stream.
steps people take in designing and producing a product.
detailed operation steps within cells.

2. A product family matrix is used in value stream mapping to:

A. Create a listing of all your products and the steps that are taken to
produce them.
B. Decide which products are most important to your customers.
C. Identify and group products into families based on whether they pass
through similar steps in your downstream processes.
D. Divide the mapping teams up into groups with groups with individual
mapping assignments.
3. The recommended level for beginning to map a value stream for a product
family is:
A.
B.
C.
D.

Corporate wide.
Door to-door in an individual facility or plant.
Across multiple facilities.
At the process level, for example in a single work-cell.

4. Calculate the Takt Time based on the following information:

Customer demand is 34,400 parts per month. The company works 5 days per
week and on average 20 days per month. There are two, eight hour shifts.
Lunch is 30 minutes per shift. Two, ten minute breaks are taken per shift.
The calculated Takt Time is:
A. 0.5 minutes per part or 30 sec. per part.
B. 1 part per minute or 1 part every 60 sec.
C. 0.5 parts per minute.
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
D. 1 minute per part.
5. Data Boxes on a value stream map should contain information based on:
A.
B.
C.
D.

Engineering standards.
The average measurements over the last year.
The measurements on an ideal or typical day.
What you observe on the day you draw your map.

6. Give three examples of information that could go in a value Stream Map data
box:
1. ________________________________________________________________________________
2. ________________________________________________________________________________
3. ________________________________________________________________________________
7. One of the biggest mistakes in implementing Lean Manufacturing is:
A. Sub optimizing by conducting Kaizen events in areas without first taking a
big picture view of the organization.
B. Not implementing improvements in line with organizational strategy.
C. Skipping the value stream mapping step.
D. All of the above.
8.

List the eight questions you generally ask in order to create your future state
value stream map:
1. ________________________________________________________________________________
2. ________________________________________________________________________________
3. ________________________________________________________________________________
4. ________________________________________________________________________________
5. ________________________________________________________________________________
6. ________________________________________________________________________________
7. ________________________________________________________________________________
8. ________________________________________________________________________________

9. A supermarket is used where:

A. Processes are close together but have different cycle times.
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
B. A customer requires specialized products from the finished goods
warehouse.
C. Continuous flow is not possible due to distance, unreliability, or where
process serves multiple product families.
D. Pull can be implemented throughout the door-to-door value stream.
10.

Creating value stream loops after future state mapping helps you to:
A. Break your total value stream plan into manageable pieces and prioritize
them.
B. Communicate your plan to senior management.
C. Assign kaizen teams to be responsible for each loop.
D. Develop measures for each loop based on improving lead times.

11.
List at least three specific forms from your 5S course you could use and
complete that would be useful in 5S activities?
1. ________________________________________________________________________________
2. ________________________________________________________________________________
3. ________________________________________________________________________________
12.

5S (choose best answer below)

A.
B.
C.
D.

Is about standardizing the way we do things.

Forms a foundation for all other improvement activities.
Is a key to reducing inventory to improve lead time?
Cannot be used in an office or administrative area.

13.
Match the 5S steps to their appropriate description (fill in the appropriate
letter):
5S Launch _____
Sort
_____
Set in Order _____
Shine
_____
Standardize _____
Sustain
_____
A. identify best locations for items, relocate out of place items, set inventory
height and size limits, focus on safety, install temporary location
indicators.
B. Involves forming a core implementation team, identifying a project using a
team charter, performing a Workplace Scan and display.
C. Create rules such as holding rules and responsibilities; locations, number
and position of items; cleaning schedules and procedures; storage and
retrieval systems; visuals controls to share information and highlight
conditions.
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
D. Look at items in work area, red tag, keep whats needed/eliminate whats
not, and reduce number of items to whats required.
E. Develop awareness and skills, make 5S part of daily work, get
commitment from top management to make time for 5S, 5S audits, and
ongoing 5S communications.
F. Identify sources of containment; determine targets and assignments for
cleanliness; make everything like new, check if replacement or repair is
necessary; replace wires, hoses, tubes, etc.
14.

5S efforts often fail to be sustained because:

A. Everyone is involved.
B. Managers dont allow or make time for 5S activities and organizations fail
to adequately implement the sustain step.
C. 5S isnt really value-added.
D. Managers implement 5S but employees dont do the work to keep it up.

15.

Check all that apply to goals of Mistake Proofing

_____
_____
_____
_____
_____
_____
_____
_____

Eliminate problem people

Make product with zero defects
Remove process variables reducing opportunities for mistakes
Make it impossible to make mistakes
Repair defective product
Make things right with the customer including recalls and repairs
Immediately detect defects if they occur
To catch and fix human mistakes

16.
Please match the method with the appropriate description or example of
mistake proofing:
_____
_____
_____
_____

Contact/Physical Contact Device

Performance Step/Motion-Step Device
Fixed-Value Device
Operator Initiated Controls/Doing It Right Device

A. A parts feeder automatically counts out the nine bolts required for
assembly when the operator presses a lever. The part assembled with the
nine bolts isnt allowed to leave the station unless all nine bolts are
installed.
B. Proximity switches mounted on sides of a blank plate trip when the blank
is properly positioned allowing the machine to start. If switches are not
tripped, the machine wont start.
C. Color-coding one side of a part so it is assembled with the correct side up.
D. A photoelectric switch is connected to a timer; if movement of the part
doesnt occur when it should at the right step in the process (for example,
it is forgotten by the operator), the switch signals the machine to stop.
17.

A major barrier to inventory reduction and batch size reduction is.

jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
A.
B.
C.
D.

Long set-up changeover times

5S activities
Lead time reduction
Material handlers

18.The economic lot size model indicates a trade-off between changeover and inventory
cost. One incorrect assumption with the model is:

A. Fast changeovers increase flexibility

B. High inventory and fast changeovers are good.
C. We have to live with long set-ups and large batches; set-up times cannot
be reduced
D. There is a point where the cost of a changeover exceeds inventory
carrying costs
19.Set-up Time is typically classified in two categories as:

A.
B.
C.
D.
20.

Internal or external
Value-added or non value added
Motion and transport waste
High cost and low cost

Please circle the incorrect statement:

A. Policy deployment is Management By Objectives (MBO).
B. Policy deployment develops a one year plan reflecting the long-term vision
and 3-5 year strategic planning objectives.
C. Policy deployment is a planning-implementation process that focuses on a
few major long-term customer-focused breakthrough objectives.
D. Policy deployment ensures individuals are aligned and understands what
improvements are important to work on.

21.
Circle the correct statement regarding Policy Deployment and Breakthrough
Objectives
A. Breakthrough objectives are predominantly a supervisor function.
B. Effective strategic planning should facilitate the identification of
breakthrough objectives.
C. Breakthrough objectives are not stretch objectives and represent smallstep improvements.
D. Is rarely customer focused.
22.
You know you have correctly identified a root cause and implemented
effective corrective action through 8D because:
A. You contain the effects and address the symptoms of the immediate
problem.
B. You have implemented a solution that meets budget constraints.
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
C. The problem disappears so you never have it again; you can turn it off/on
during testing.
D. You have done a job of putting a quick fix in place.
23.
Establishing
on-going
controls,
updating
related
documentation,
standardizing new practices, updating personnel is part of which 8D step or
steps:
A.
B.
C.
D.
24.

5W2H (who, what, where, when, why, how, how many) is used:
A.
B.
C.
D.

25.

Verify corrective actions.

Implement permanent corrective actions.
Prevent recurrence
Both B and C

During the Describe the Problem phase to help define the problem.
Help in the Implement and Verify Interim Actions phase.
To Define and verify the root causes.
Both B and C.

Identify the statement that fits the proper term:

A. Containment/Interim Action.
B. Corrective Action.
C. Preventive Action.
_____

Action taken addresses the system failure that allowed one operator to
go untrained in the first place

_____

Action taken to prevent occurrences of a problem which has never

occurred such not allowing smoking in the building to prevent the first
time occurrence of a fire in the building

_____

Action taken is to retrain the operator to follow

procedures in response to a problem that occurred

26.

the

proper

Select the non-value added activity:

A.
B.
C.
D.

Assembling two parts together

Extrusion machine making parts
Packing parts for shipment
Picking up a part, putting it down and picking it up again

27.
Making something earlier or faster than required by the next process
just-in-case is an example of which type of waste?
A. Defect
B. Motion
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
C. Overproduction
D. Over-design
28.

List four types of waste:

A.
B.
C.
D.

_____________________________________
_____________________________________
_____________________________________
_____________________________________

29.
When a process runs out of control, the process must be investigated for
the need of adjustment.
True.
_____
False. _____
30.
P-charts show the percentage of the number of parts rejected to the
number of good parts.
True. _____
False. _____
31.

What do the initials TPM mean?

A.
B.
C.
D.

32.

To
To
To
To

fix equipment only when it breaks down.

give an operator one more thing to do.
utilize worker and machine effectiveness.
reduce the involvement of other people.

What is the goal of TPM?

A.
B.
C.
D.

33.

To
To
To
To

fix equipment only when it breaks down.

give an operator one more thing to do.
utilize worker and machine effectiveness.
reduce the involvement of other people.

Name 4 of the big six equipment losses.

1.
2.
3.
4.

34.
be:

_____________________________________
_____________________________________
_____________________________________
_____________________________________
An example of a counter measure to the source of contamination would

A. Container for master parts with lids.

B. Splash guards and deflector plates.
C. Repairing all water and oil leaks.
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
D. All of the above.
35.

Some failures happen in which causes?

A.
B.
C.
D.

Deterioration.
Contamination dirt.
Disassembly.
All of the above.

A.
B.
C.
D.

When carrying out inspection on equipment, we are making use of:

Our sense of vision.
Our sense of touch.
Historic data to track trends.
All of the above.

36.

37.

Which two are examples of preventive shine?

A.
B.
C.
D.

38.

Mopping up after the floor gets dirty.

A door mat.
Sweeping the mat.
A waste chute catching and directing waste directly in a trash can.
A Kanban system supports a pull system.

True. _____
False.
_____
39.
A pull production system is a production system where you make as
much product as you can regardless of whether the customer needs it or not.
True. _____
False.
_____
40.

Please circle the items listed below that are preconditions for Kanban.
A.
B.
C.
D.
E.
F.

5S: workplace organization.

Level scheduling.
Long break times.
Standard work.
Extra inventory.
The following process (customer) picks up parts from the previous process
(supplier).
G. Quick changeovers.
H. 100% quality is mandatory.
I. Machines operate correctly when they are needed (TPM).
41.

Please circle the items listed below that are Kanban Rules.

jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
A. Produce only the amount taken by the following process (customer).
B. When the first part is removed from the container, the Kanban is removed
and placed at the Kanban post.
C. It is acceptable to wait until the next shift to place the Kanban at the post.
D. No production or material moves are performed without a Kanban.
E. It is acceptable to lay a Kanban on a workstation or put a Kanban in your
pocket until you get time to take it to the Kanban post.
F. Defects are never passed onto the next process (customer)
G. It is necessary to periodically review the number of Kanbans issued.
H. Finished goods should be located at the production location for visual
management.
42.
Please circle the items listed below that may result from breaking the
Kanban Rules.
A.
B.
C.
D.
E.

Under production.
Over production.
No overtime.
The extra inventory will hide defects and problems.
The cost of production will increase.

43.
Describe how you see that Panera Bread has made use of or implemented
Lean Manufacturing techniques and principles in the past? List 5 examples for a
total of 5 points?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
44.
Describe how and even where you feel Panera Bread can use Lean
concepts and techniques for future improvements? List a minimum of 2
examples for a total of 5 points.
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

Revision Date 02/20/11

Learning to See
45.
Describe how you would like to participant in the Lean improvement
efforts at Subway? Where can you use the Lean Concepts to help Subway?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________

jpetak@exerciselean.com
www.exerciselean.com
115 North Orchard Farms Avenue
Simpsonville South Carolina 29681

10

Revision Date 02/20/11