Question 1

Which of the following key lean measures for quality includes the measure of potential process capability?

Accepted Answer

A) Defects per unit. 
B) The ratio of the six sigma spread of a process distribution to the tolerance of the distribution, also known as Cp. 
C) Cpk, which is calculated by dividing the distance of the process mean to the nearest tolerance limit by 3 standard deviations of the process. 
D) A Defects Per Million Opportunities (DPMO).

Question 2

Lean cost and productivity measurements may include employee labor productivity and individual or group sales productivity. Calculate the number of products produced per hour by a factory that produced 16,000 items with 8 employees working 8-hour shifts 5 days per week, with a total of 40 hours each per week, for 4 weeks.

Accepted Answer

A) 16 products per hour 
B) 12.5 products per hour 
C) 42 products per hour 
D) 7 products per hour

Question 3

A trigger event occurs when a condition exceeds established process parameters, values, or normal conditions. Once a trigger event has occurred, what is the next step?

Accepted Answer

A) To determine if the process error was human in nature. 
B) To determine what condition requires an immediate response. 
C) To determine if the event was caused by equipment error or maintenance. 
D) To begin collection of data on the process parameters.

Question 4

Normal conditions are those we expect to meet a certain standard. Abnormal conditions are those which do not meet the standard. Which of the following factors does NOT impact a reaction to abnormal conditions?

Accepted Answer

A) An employee is assigned ownership for the abnormal condition. 
B) Visual indicators make the abnormal condition easily visible. 
C) The standard must be known by employees and followed. 
D) No set standard of identification is required.

Question 5

Lean metrics typically fall into the two categories of results or drivers. What do driver metrics tell you?

Accepted Answer

A) Behavior changes which need to be made down the road. 
B) Future operational planning parameters. 
C) Financial indicators, both positive and negative. 
D) Immediate feedback on how a process is running.

Question 6

In order to drive performance the organization must create value for lean within the organization's culture. Which of the following factors enables the organization to create lean value?

Accepted Answer

A) A visual management system that makes problems visible. 
B) A technical resource center. 
C) Outsourcing of logistical supply operations. 
D) Purchasing additional exercise equipment for employees.

Question 7

Rework measures are critical to operationally monitoring the level of waste caused by having to redo or rework a product. What does a First-Time-Through (FTT) rework measure?

Accepted Answer

A) The effectiveness of the cell's standardized work. 
B) The accuracy of measurements for the process. 
C) The attention to detail for employees. 
D) Costs of products scrapped because they require rework.

Question 8

Lean measurements such as safety, quality, financial, employee, and responsiveness have a competitive impact in corresponding balanced scorecard measures. What measure would include the amount of manufacturing space used?

Accepted Answer

A) Lean quality measurements. 
B) Lean responsiveness measurements. 
C) Lean financial measurements. 
D) Lean safety measurements.

Question 9

Changeover time is a critical lean measure in processing plants and manufacturing environments. SMED (Single-Minute Exchange of Dies) is a system for reducing the time it takes to complete equipment changeovers. Which of the following is NOT one of the benefits of SMED?

Accepted Answer

A) Larger lot sizes with faster changeovers. 
B) Lower inventory levels. 
C) Improved response to customer demand. 
D) Lower manufacturing costs.

Question 10

Which quality measure for business results would be used to measure repetitive wear and tear on employees working on an assembly line?

Accepted Answer

A) Ergonomic management. 
B) Targeted training hours. 
C) Days worked without a lost time accident. 
D) Reportable incidents.

Question 11

Measurements should be tied to the customer and their desires. The desires of the customer impacts whether your product meets their needs. Which of the following questions would you NOT consider to be an interview question for a Voice of the Customer Analysis?

Accepted Answer

A) What would threaten the potential of you doing future business with us? 
B) Why should we continue to do business with you? 
C) What do you like about our current processes? 
D) What do you feel needs improvement in our current processes?

Question 12

Measures and measurement systems are interdependent. Individual measures are tested in the measurement system to develop an analysis. Which metric element requires that the exact calculation of the metric be known?

Accepted Answer

A) The frequency of the measure. 
B) The objective of the measure 
C) The unit of the measure. 
D) The formula for the measure.

Question 13

Understanding customer demand and characteristics requires understanding of the "pull" of customers. Customer demand affects which of the following?

Accepted Answer

A) Kanban quantities. 
B) Determination of Takt time. 
C) Both A and B. 
D) Process capability for attributes.

Question 14

Cycle time is a key lean measurement in supply chain management and in lean enterprise planning. Which of the following is a measure of production cycle time?

Accepted Answer

A) It begins when an online order is placed and ends when sent to the production floor. 
B) It begins when an order is released on the production floor and ends when the product is available for shipment to the customer. 
C) It begins when the production line starts to move and ends when the customer signs for the product. 
D) The total of each separate time in the cycle to produce the good.

Question 15

The performance factor for Overall Equipment Effectiveness (OEE) is the speed with which the machine or process produces products compared to the design speed or normal operating cycle. Which of the following correctly shows the formula for OEE?

Accepted Answer

A) Availability x Performance x Quality. 
B) Opportunity x Precision x Errors. 
C) Time/Down Time x Cost. 
D) Error Rate x Throughput.

Question 16

Employees have to be developed to improve their capability with lean and sustain lean improvements. Which of the following is NOT an action management would take to be viewed as supportive in terms of "people development measures"?

Accepted Answer

A) Assessing the lead time in the production environment. 
B) Assessing the management environment for level of lean engagement. 
C) Identifying and optimizing competencies required for lean. 
D) Describing roles and problem solving responsibilities in the strategic context.

Question 17

Reporting of measurements helps to speed improvements. The most effective measurement factors would include which of the following?

Accepted Answer

A) The ability to replicate data. 
B) Using the most number of data sources possible. 
C) Reliability of the measures of the system. 
D) The ability to reproduce gage.

Question 18

Which key lean measure for "delays" would be affected if special packaging or pallets were required to ship a good?

Accepted Answer

A) Outside Processing Time. 
B) Shipping Transit Time to Customer. 
C) Process Time for Individual Step. 
D) Material Lead Time.

Question 19

Measuring goals and objectives for service industries may require developing metrics for service. Which of the following would be considered a service metric?

Accepted Answer

A) A frozen dinner takes less than 3 minutes to microwave. 
B) A wait time on the phone of less than 15 seconds. 
C) An assembly line processes a package of cereal in 1.8 minutes. 
D) A copy job takes 7 minutes to print.

Question 20

Lean accounting measurement is used to support lean thinking within the organization. In traditional accounting, waste is hidden. Which of the following is NOT one of the ways in which traditional accounting measures hide waste?

Accepted Answer

A) Incorrect standards. 
B) Inadequate reporting in production, design, or sales. 
C) Incorrect accounting formats. 
D) Overhead allocations for the organization.

Exam 1: Business Results