Lean Implementation Question Answer

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1 Defect prevention is Mistake proofing Iterative testing OA Early testing Mistake proofing
2 ______________ is the critical starting point of Lean thinking Project Value Customer Value Value Addition Program value Customer Value
3 To get First Hand Information, we need to do Visual Control Go See Yourself Brainstorm Continuous Monitoring Go See Yourself
4 Value is always defined from the perspective of the Customer Project Product All of the above Customer
5 ______________ is a Visual Control device in the work area indicating a process or quality problem Andon Board SMED Both 1 and 2 None Andon Board
6 ______________ is the rate (time per unit of value) at which work should proceed through a Value Stream Cycle Time Activity Time Takt Time All the above Takt Time
7 This technique can be used to conduct root cause analysis 5 Why Fishbone diagram Cause and Effect diagram All the above All the above
8 Pull system helps in avoiding ______________ Over production Slow production Fast production None of above Over production
9 Placing everything in its place is part of _________________in 5S framework Sort Straighten Shine Sustain Straighten
10 Creation of a level schedule by sequencing orders in order to smoothen the demand is known as ______________ Heijunka Gemba Kaizen Hoshin Kanri Heijunka
11 Kaizen as implemented in Lean helps in the following Ongoing improvement significant onetime improvement Ongoing small changes suggested by external process consultant One time significant change suggested by external process consultant Ongoing improvement
12 Continuous organization learning and improvement is ensured through ______________ Standardization and Automation Retrospection and Mistakeproofing Pull and Flow Retrospection and Kaizen Retrospection and Kaizen
13 Main purpose of Visual control is to Create dashboards and metrics for measurement Ensure problems are not hidden Help in baselining and measuring the trends Showcase to the management on the success stories of the team Ensure problems are not hidden
14 VSM helps in Identifying areas where automation can be implemented Identifying areas for putting mistake proofing process Identifying value adding and non value adding activity in a process Identifying areas where Visual control can be implemented Identifying value adding and non value adding activity in a process
15 PDCA stands for Plan-Do-Check-Act Plan-Do-Control-Analyze Plan-Do-Check-Analyze Plan-Do-Control-Act Plan-Do-Check-Act
16 Which of the following is not a root cause analysis technique Pareto diagram 5 Why Fish Bone Diagram Mistake Proofing Mistake Proofing
17 The culture of Lean gives a lot of importance to Innovation Capability building Questioning status-quo Showcasing best practices Questioning status-quo
18 Identifying the necessary and removing unwanted one in any workplace is called Straighten Automation Mistake proofing Sort Sort
19 What is the typical first step towards identifying the area of waste elimination in a project Root Cause Analysis 5S Mistake proofing Value Stream Mapping Value Stream Mapping
20 Kaizen applied with the right approach helps in achieving Quantum improvement Incremental improvement Sustains the performance Marginal improvement Incremental improvement
21 ‘Value’ in Lean terms is a deliverable to the client which is usable. Identify which statements below qualify for this Value definition Value for a recruitment group is each human resource made available to the project teams Value for a Maintenance project is the Bugs serviced per release Value for a Conversion project is every web page converted All of the above All of the above
22 Identify Type 2 “Waste” in these scenarios Waiting and searching for resources in the lab during reproduction and testing Capturing relevant information in defect tracker Updating knowledge base Frequent build cycles, frequent code reviews and early testing Waiting and searching for resources in the lab during reproduction and testing
23 Workload leveling is Assiging important tasks to key resources only Allocating the tasks as and when they queue up Allocating the right tasks to team members based on effort,complexity estimates, skill level Dividing and assigning the same tasks to multiple people Allocating the right tasks to team members based on effort,complexity estimates, skill level
24 What is Lean? Creating value from the perspective of a customer Improving processes and operation A culture of continuous improvement All of the above All of the above
25 When should I start implementing Lean principles in a project? When the organization mandates When there is a problem in the project When the project gets kicked off None of the above When the project gets kicked off
26 During which phase of the project can Lean be implemented? Requirement phase Design phase CUT & ST phases All of the above All of the above
27 The delivery team uses white boards to monitor the status of the tickets, automates routine jobs, maintains checklist and implements learning from previous releases. The team does not have a knowledge of Lean and has never attended any Lean training sessions. Is Lean being practiced in the project Yes No Can’t answer None of the above Yes
28 The management decisions in a company practicing Lean philosophy is based on Waste elimination Short term financial gains Long term thinking even at short term financial expense Medium term thinking but with high operating margins Long term thinking even at short term financial expense
29 Which of the following are two key pillars of the Toyota Production System? Just-in-Time and Waste Elimination Jidoka and Just in Time Visual Management and Kaizen Standardisation and Leveled Production Jidoka and Just in Time
30 The culture of stopping when there is a quality problem is called Waste elimination Standardisation Jidoka None of the above Jidoka
31 Which of the following is a technique involving simple inexpensive automatic mechanisms or manual inspection in a station, that makes the quality issues obvious at a glance? Visual Control Value Steam Mapping both 1 and 2 Poka Yoke Poka Yoke
32 The roots of Lean thinking can be traced back to Harvard GE Honda Toyota Toyota
33 Lean principle is based on management decisions adopting a _____________ philosophy” Short Term Medium Term Long Term All of the above Long Term
34 What is the main purpose of Visual Controls? To show status to upper management To show status to customer To bring out operational problems affecting for early resolution None of the above To bring out operational problems affecting for early resolution
35 Which of the following is NOT part of 5 S? SORT Straighten Soften Standardize Soften
36 Takt time is a ratio of the ‘Net available time’ to ________________ Total Supply Customer demand Both None Customer demand
37 Poka Yoke is ______________ Mistake Proofing Visual Control Standarization None of above Mistake Proofing
38 The “5 Why?” is a ______________ technique 5 S RCA DSM None of the above RCA
39 Lean thinking advocates ______________ Push Systems Pull Systems both None Pull Systems
40 Andon board is an example of ______________ Visual Control Dashboard Network diagram None of the above Visual Control
41 To reduce test setup change-over time, you considered SMED technique. Which of the following principles can help? Displace Eliminiate Standardize All of the above All of the above
42 Customer expects the team to test 10 features in 20 working days. What is the takt time? 10 features/month 2 days/feature 0.5 features/day None of above 2 days/feature
43 Which of the following is a part of the Lean philosophy? Management decisions based on a long term perspective Stop when there is a quality problem Leaders going to the actual workplace to see and understand throughly All of the above All of the above
44 Following are categories of waste Overproduction Transportation Motion All of the above All of the above
45 An effective way to make team memebrs aware of progress made and currents status is through Visual Boards Poka – yoke Mura Muri Visual Boards
46 Mistake proofing is Andon Poka – yoke Mura Muri Poka – yoke
47 Over production is avoided by using ___________ Pull system Poka – yoke Mura Push system Pull system
48 How many Lean principles are there according to Jeffrey Liker as presented in “The Toyoto Way” 5 10 14 None of the above 14
49 How many categories of wastes can be identified as per the Toyota Production System? 7 10 100 20 7
50 “Upstream should not produce anything till downstream asks for it” is a part of which Lean principle Poka- yoke DSM Push Mechanismans Pull mechanism Pull mechanism
51 The practice in 5S framework by which the work place efficiency is maintained is ________________ Sort Shine Sustain All of the above Sustain
52 “Pace of production to meet customer demand” is related to _______________ Takt Time Talk Time Delay time All of the above Takt Time
53 Spending time to finding information can be mapped to _______________ waste Overproduction Inventory Motion All of the above Motion
54 A tool in the work area giving the current status of the work Visual Control Board SMED Both 1 and 2 None Visual Control Board
55 Employing tools to do work otherwise done by people results in reduction of ___________ Efforts Schedule Defects 1, 2 and 3 1, 2 and 3
56 Automated detection and stopping when a defect occurs is related to ___________ Automation Jidoka (autonomation) Genchi Genbutsu Visual Controls Jidoka (autonomation)
57 In TPS, high levels of quality is achieved by the principles of Jidoka Poka Yoke Both 1 and 2 None Both 1 and 2
58 According to Lean thinking, problems should be addressed at Root Cause level Manager level Operator level All the above Root Cause level
59 Kaizen can result in an improvement in _______________ Quality Throughput Both 1 and 2 None Both 1 and 2
60 Problems identified are displayed for everyone’s attention rather than covering up Make the problem visibile Make it fast Make it beautiful None Make the problem visibile
61 Any activity that consumes resources, but does not create value is _______________ Muda Mura Muri All the above Muda
62 Tasks with clear specification on the input, process, time and output are _______________ Fixed standardized Designed All the above standardized
63 Identification of all activities occuring along the life cycle of the product is _________ Value Creation Value Stream Mapping Customer Value None Value Stream Mapping
64 Making more parts than you can sell is _______________ Overprocessing Overproduction Both 1 and 2 None Overproduction
65 Optimization of current state map gives the _______________ Optimized map Value map Future state map All the above Future state map
66 In the 5 Why analysis, if the root cause is not identified at the 5th Why, one should _______________ Stop Start afresh Continue None Continue
67 The slowest operation in a process is _______________ Work stopper Bottleneck Both 1 and 2 None Bottleneck
68 What is the ongoing process/philosophy of doing things better, faster and lower cost? Continuous Processs Continuous Engineering Continuous Improvement None Continuous Improvement
69 Giving employees more responsibility, authority and accountability for effecting improvements that are within their purview in the daily processes is Employee _______________ Empowerment Engagement Endearment None Empowerment
70 Lean practices optimizes the Cost Qualitty Schedule All the above All the above
71 Achieving predictability of the outcome and making it repeatable is ensured through _______________ Concurrent Engineering Predictive Engineering Standardization All the above Standardization
72 Genchi Genbatsu is part of _______________ category in Liker’s 14 principle model Process People and Partners Problem Solving Philosophy Problem Solving
73 What is Hansei? Reflection Refraction Retraction Renovation Reflection
74 Problems should not remain hidden. They should be _______________ early. Standardized Optimized Surfaced All the above Surfaced
75 An engineer fixes a bug request from the customer. The customer value here is _______________ Fixed Bug No side effect Both 1 and 2 None Both 1 and 2
76 Attributes of value deliverables areTimelinessCost Quality Timeliness Cost All the above All the above
77 According to Lean thinking, leaders should work with first hand information from _______________ by direct observation. Customers Workplace Both 1 and 2 None Workplace
78 Which of the following are examples for Muda? Hand off Task Switching Both 1 and 2 None Both 1 and 2
79 In a maintenance project with a 3 month release cycle, the team idles during the first six weeks due to lack of clarity. The customer expects team to work as per the planned efforts in the remaining 6 weeks. This will lead to _______________ Task switching Overload Poor quality Both 2 and 3 Both 2 and 3
80 The purpose of VSM is to ____________ and eliminate waste Standardize Empower Identify None Identify
81 _______________ is the time taken for those activities that actually transform the product/service in a way that the customer is willing to pay for Takt Time Activity Time Cycle Time Value Added Time Value Added Time
82 Those activities that are not mandatory to provide what customer wants are _______________ Important Non Value Add Both 1 and 2 None Non Value Add
83 _______________ is an activity that transforms the input, thereby bringing it closer to the form required by a customer Value Add Muda Muri None Value Add
84 Mechanisms (other than inspection at a work place) to achieve in-station quality by prevention is an example of _______________ Jidoka Heijunka Poka Yoke All the above Poka Yoke
85 Principles of 5S aim at achieving Efficient work place Jidoka Efficient task switching None Efficient work place
86 Standardization helps to reduce variance in Cycle time Quality Both 1 and 2 None Both 1 and 2
87 Standardized work and environment are the basis for Continuous improvement Defect prevention Both 1 and 2 None Continous Improvement
88 An operating model with in-station quality is found in Mass production approach Toyota Production System Both 1 and 2 None Toyota Production System
89 Use of code analysis tools as the code is developed is an example of _______________ Concurrent Engineering In station quality first things first None In station quality
90 Kaizen is _______________ An activity that causes an incidental problem An activity that causes a recurrent problem An activity that enables continuous improvement None of the above An activity that enables continuous improvement
91 The 5 Ws of root cause analysis are Who, what, where, when, why What, where, when, who, why Who, who, who, who, who Why, why, why, why, why Why, why, why, why, why
92 Automatically stopping the process when something is wrong and then fixing the problems on the line itself as they occur is called _______________ Heijunka Jidoka Kaizen Kanban Jidoka
93 Which of the following are examples of Muda (waste) in the process which should be eliminated? Doing work manually when it can be automated Equipment not working Spending efforts in processing repetitive issues All of the above All of the above
94 Lean is _______________ Action Oriented Continuous Improvement Process toolkit All of the above All of the above
95 Lean is not _______________ Short term gain Problem Solver Action Oriented Continous Improvement Short term gain
96 The deciding factors for automation are _______________ Feasibility Return of Investment Frequency All the above All of the above
97 Understanding the actual situation is known as _______________ Capacity Planning Mistake Proofing SS Go and see Yourself Go and see Yourself
98 Use _______________ to reduce setup/changeover time SMED 5S RCA VSM SMED
99 Issue log or KEDB helps in _______________ Mistake proofing Automation VSM Competency management Mistake proofing
100 The PM defines the coding standard for a new technology before the development starts. Based on these guidelines, he also reconfigures the code review tool. Choose the Lean tenets PM has applied Standardization & Mistake proofing Standardization & Statistical Analysis Only Standardization 5S and Mistake proofing Standardization & Mistake proofing
101 What are the 5 STEPS of 5S? Shine, Solve, Sustain, Sort, Standardize Sustain, Sort, Standardize, Set, Shine Sort, Straighten, Shine, Standardize, Sustain Sort, Sustain, Sushi, Shine, Standardize Sort, Straighten, Shine, Standardize, Sustain
102 Which statements defines “VALUE”? The customer has to be willing to pay for the activity The activity must “directly transform” the item or person flowing through the process into what the customer is willing to pay for. The activity must meet all expected requirements on the first attempt All of the above All of the above
103 A checklist is a simple example for _______________ Mistake proofing Standardization SMED 5S Mistake Proofing
104 What is the first step in the VSM? Draw the Value stream mapping(As-IS) Identify the customer Value deliverable Remove the wastes Identify the Value added and Non value added activities Identify the customer Value deliverable
105 In a project X, few resources are overburdened due to disparity of competency in teams. This situation is a result of _______________ Muda Muri Mura Muri
106 Which of the following tenets is used for work place management? SMED 5S VSM DSM 5S
107 Which of the following Lean methodologies can be used to identify the waste in the process? DSM 5S VSM CMMI VSM
108 Identify the applicable tenet used for identifying the root cause of the problem 5S Statistical Analysis 5WHY PDCA 5 WHY
109 In an application maintenance project, the team was following the practice of placing a Red flag in front of the engineer who was stuck up with a problem related to resolving the incident. This is an example of _______________ Standardization Kanban Andon None of the above Andon
110 How many guiding principles does Lean have? 11 7 12 14 14
111 _____________ provides a complete visibility of all work items and status in the team Standardization Mistake Proofing Visual Control ecube Visual Control
112 TPS is an integrated socio-technical system, developed by ____________ Ford Toyota Wipro IBM Toyota
113 Which of the following is not part of 5S? Sort Sustain Shine Sequence Sequence
114 According to Womack Lean thinking consists of __________ core principles 3 7 14 5 5
115 Which of these are not a core Lean principle according to Womack Pull Flow Value Push Push
116 The principle of flow emphasizes on __________ reduction in batch size Moving to next phase as quickly as possible Individual productivity Customer satisfaction reduction in batch size
117 SMED stands for _____________ Single Minute Exchange of Dies Simply More Energy Daily Simplest Most Effective Design Sampling Method for Effort Deviation Single Minute Exchange of Dies
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