Lean Bronze Certification Practice Exam

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• The goal of Hoshin Kanri is
• The takt time number means:
• Which 5S step is described by 'Keep workplace neat and clean'?
• What is the first step to cellularizing a production line?
• Which company created the first moving assembly line?
• In Sustain, visual cues provide:
• Which statement about takt time is true?
• Which option is listed as a Lean waste under the concept of Knowledge Disconnect?
• Which PDCA phase is used to assess results after an improvement cycle?
• Lean techniques define value from the perspective of whom?
• A tool used to implement a pull system is:
• Which term describes leveling production to smooth out volume and mix in kanban systems?
• What method supports Sustain?
• Sustain includes establishing systems for:
• In which element is Takt Time commonly included?
• In lean process analysis, which term describes unevenness in work and demand flow?
• Which statement best defines value-added work in a lean system?
• If Sustain is not practiced, gains tend to:
• What is a Kaizen event typically used for?
• If Availability is 100%, Performance is 100%, and OEE is 90%, what is the Value Stream Quality percentage?
• Which statement best reflects the relationship between Kaizen and Kaikaku?
• Pitch equals takt time times pack-out quantity.
• A manufacturing plan with a high level of Muri indicates what about the workers?
• What are the three elements of standard work in lean production?
• In TPM, which is an example of a hidden failure?
• Which element is described as foundational in lean systems?
• Kaizen is a Japanese word meaning "change for the good", or continuous improvement. Which process best describes kaizen?
• Which of the following is not a lean waste?
• Which term is commonly used for a small cross-functional team formed to tackle a specific problem quickly?
• Standardizing and stabilizing the process are necessary steps:
• In a production line, a common sign of a bottleneck is
• A visual management system in Sustain helps by:
• Lean manufacturing is derived from the TPS; the fundamental concept behind lean manufacturing is the elimination of?
• Catch ball is typically deployed in which process?
• Which diagram is commonly used to analyze the flow of people and materials in a facility?
• Which cycle is associated with the Deming philosophy and is cited in Lean as a core improvement loop?
• In a process with a takt time of 3 minutes and a pack-out quantity of 35 parts, the Pitch is
• In a lean system, who should establish production standards?
• Sustain is primarily about preventing backsliding by:
• Which statement best describes standardized work?
• Who are pioneers of Just in Time techniques in Toyota?
• Sustain ensures that improvements are:
• What is the ultimate goal of lean?
• Calculate the availability component of OEE using the data: Scheduled to run 16 hours a day, 5 days a week; Planned stop production 60 min each day for 5S activities; Lost 3 hours this week due to machine breakdowns; Lost 2 hours this week due to material shortages.
• In 5S, the Red Tag area is used to identify items that are
• In value stream mapping, who defines value at the outset?
• Which tool is described as helping to understand the different value streams in lean systems?
• In a 5S program, red tagging is used to
• Which statement about takt time is true?
• Little's Law states that WIP equals what combination of Throughput and Lead Time?
• Which term refers to the set of actions that move a product through the essential flows, including both value-added and non-value-added steps?
• Which method determines the optimal number of workers by aligning work with the line's flow?
• What is the primary objective of Poka-Yoke?
• Among the seven wastes, which is considered the worst?
• In lean Manufacturing, which term describes fluctuations in process performance (uneven)?
• Batch processing creates which of the following?
• One-piece flow in Lean refers to which production approach?
• Which lean practice is specifically concerned with reducing downtime during transitions between products?
• Gemba in lean thinking refers to the what?
• Which 5S term corresponds to standardizing processes?
• In lean thinking, which statement best captures the relation of stability?
• What term describes the practice of a downstream process going to the upstream process to retrieve product?
• The amount of time it takes to complete one piece at a process step is known as
• Which Lean term refers to waste from unnecessary motion, inventory, and processing steps?
• Which Lean process is designed to align resources and strategic goals across the organization?
• Given a takt time of 180 seconds and cycle times of 160s (Cutting), 190s (Deburring), 192s (Inspecting), and 194s (Packing), which process is the bottleneck?
• Making parts just in case is an example of which Lean waste?
• Management by walking around is most closely related to which concept?
• Time study and standardized work is based on the work of whom?
• The amount of stock kept on hand to compensate for variation in supplier lead time and upstream processes is known as:
• In evaluating Overall Equipment Effectiveness, which item is not considered in the calculation?
• Sustain requires that standard work be:
• Which of the following is a direct consequence of batch processing in manufacturing?
• Which theory describes the relationship between WIP, throughput, and lead time?
• Takt time is the rate at which a product must be produced to meet customer demand.
• What is the primary focus of Kaizen?
• What is described as the basis of the Toyota Production System in the provided material?
• With 960 minutes of available time, demand 200 units, and an OEE of 85%, what is the takt time?
• Which activity best supports Sustain?
• Which is an enabler of a lean culture?
• Leadership must protect the working environment and the health and safety of all employees, in order to maintain respect. What is NOT included in assuring a safe environment?
• Learning to See is widely regarded as the foundation of which lean tool?
• If a multi-step manufacturing process has its capacity limited by a single workstation, which action most directly increases overall capacity?
• Given a shift of eight hours with 20 minutes breaks, process time 1 minute, setup 15 minutes, and an interval of 60 parts, what is the capacity?
• What is the first step when creating a value stream map?
• Which problem-solving process is most commonly associated with Six Sigma?
• What is the foundation of Toyota's House of Lean?
• A physical device that prevents an operator from installing a component in the wrong orientation is an example of which concept?
• To improve end-to-end flow, which should be identified and mapped?
• Which of the following is the reason for the standardization of a process?
• What should you expect from a SMED (single minute exchange of dies) implementation?
• Which of the following are characteristics of craft manufacturing?
• Sustain metrics often include:
• Which of the following is a Japanese management philosophy used to increase time between failure of a piece of machinery?
• In a Sustain-focused review, you should examine:
• Which statement best describes the purpose of a Value Stream Map in Lean management?
• If takt time is 30 seconds and a process step has a cycle time of 22 seconds, how long is the waiting time per cycle at that step?
• Which diagram, when eliminating barriers to flow, uses graphical symbols to depict the nature and flow of steps within a process?
• Which statement best describes takt time?
• Which term describes all actions required to move a product through the main flows?
• Which of the following made Fordism unsustainable?
• Quality at the source is a principle where quality is measured at every level of a process, not just at the endpoint. What would quality at the source impact?
• What would a project team do during the 4th step of a 5S implementation? (self-discipline is last of 5s)
• Which of the following is NOT defined by Muri, Muda, Mura?
• Which 5S step corresponds to "Set in order"?
• Which technique is used to determine the optimal number of workers by ensuring an even workload across tasks?
• Which practice is least associated with Sustain?
• Hour by hour charts are an example of which lean concept?
• Which tool is used to drill down into the root cause by repeatedly asking 'why'?
• If work-in-process is 10 pieces and cycle time is 2.5 days, what is the throughput rate?
• Which term describes a radical change in lean improvements?
• Quick changeover is a lean principle used to:
• Takt time refers to:
• For a process where takt time is 50 seconds and the pitch is the product of takt time and pack-out quantity, which option correctly states the pitch when the pack-out quantity is 1?
• An effective Sustain plan includes:
• Which waste could be corrected by pulling demand from the customer?
• In a lean factory, who is responsible for developing work standards?
• What is the primary goal of continuous flow in a production system?
• Kanban is a tool to support:
• What is the first step to identify waste on a selected production line according to lean principles?
• Which 5S step is described by 'Keep needed items in the correct place to allow for easy and immediate retrieval'?
• Which of the following is NOT a core element of the TPS?
• Which principle used in lean would allow an employee to have autonomation?
• Which lean concept is defined as automation with a human touch?
• Which combination is listed as an enabler to separating man from machine?
• A value stream is the entire sequence of work required to bring a product from what to delivery?
• Which 5S step is described by 'Method by which sort, straighten, shine is made habitual'?
• Which of the following is not considered one of the seven plus one wastes?
• Which term describes incremental continuous improvement?
• Which term describes measurements used to gauge problems and guide improvement in lean systems?
• What is the primary purpose of safety stock in supply chain management?
• Which lean analytical tool helps identify the root cause of a problem?
• What is a key difference between mentoring and coaching?
• Which Lean concept is used to level production to match demand?
• Why did the first implementation of lean techniques by American automotive companies often fail?
• What is the purpose of value stream performance analysis?
• Which waste is identified as the 'Mother of all wastes' in lean thinking?
• The description of employees from different areas coming together to complete a task or solve a problem is described as which type of team?
• When you identify a bottleneck, the first step should be to
• Which of the following is not typically listed as a Lean waste?
• What is the primary purpose of mapping the value stream?
• What term describes machines that automatically reveal problems?
• Which Lean tool is designed to prevent human errors from causing defects?
• Which term describes work performed by a person?
• When using the Ishikawa (Fishbone) Diagram, potential causes are grouped by which categories?
• For most unimproved processes, the proportion of value-added work relative to total activities is approximately:
• Time that does not add value to the product but is part of the process is called
• Which is NOT an element of an effective idea-management system?
• An important part of a Lean culture is people development - which of the following is NOT an example of people development?
• The heart and soul of a lean organization according to Masaaki Imai (Gemba Kaizen) is what?
• Which maintenance philosophy aims to increase time between failures?
• W. Edwards Deming is associated with what Lean tool or technique?
• With a takt time of 180 seconds and cycle times of 160s, 190s, 192s, and 194s, what is the greatest waiting time?
• Which statement about Hoshin Kanri is consistent with the material?
• In a production line, pulling a cable to stop the line is an example of which visual control tool?
• Which term is described as the foundation for stability in the House of Lean?
• The system used for managing and ensuring the flow of production materials in a just-in-time production system is known as:
• Which statement correctly describes the relationship between process stability and process capability?
• Which statement is true about the objective of Just in Time in lean practice?
• Which practice best supports reducing operator-to-operator variation?
• Which Kanban signal specifies the kind and quantity of product the downstream process may pull?
• Which statement describes the basis of the Toyota Production System based on the material?
• For a single 8-hour shift with 20 minutes of breaks and a daily demand of 230 units, takt time is:
• What is the name for an activity that is non-value added but necessary?
• Which task is used to map the current state of the production process from start to finish?
• A commonality between sports and work is the ongoing need for:
• In the 5S methodology, which step is commonly associated with communication and training?
• Lead Time is the total time from order to delivery.
• Which 5S step is described by 'Keep needed items from unneeded items and eliminate the latter (Red tag area)'?
• Which waste is described as the worst because it opens the door to other kinds of waste?
• What term describes measurements used to gauge problems, set targets, study impact of improvements, check results, and adjust?
• In 5S, what is the primary objective of Sustain?
• Which are the Pillars of TPS?
• Which tool is most appropriate for visualizing a process and identifying root causes?
• Which item is considered the 8th waste in Lean's extended framework?
• Which of the following are common causes of the waste of waiting?
• Which statement about just-in-time concepts is true?
• According to lean Production Simplified, what should we do instead of blaming people for failures?
• Which of the following is NOT true about Hoshin Kanri?
• Which of the following is NOT a way to describe Gemba?
• To sustain gains, management should:
• Which term describes producing only what is needed, when it is needed, to avoid excess inventory?
• The purpose of Takt time is to:
• From the ideas system perspective, which feature most supports sustained engagement?
• In 5S, the activity 'Sort' primarily focuses on:
• One of the foundations of the Toyota Production System is standardized work. Its purpose is to:
• In its purest form, when items are processed and moved directly from one process to the next one piece at a time, it is known as:
• Which description best defines Autonomous Maintenance in TPM?
• OEE is typically calculated as the product of which three components?
• In Lean, what signaling mechanism triggers replenishment in a pull system?
• During the 5S sort phase where should we put items we don't think we need?
• Which term describes the practice of making a production line adaptable to different products with minimal changeover?
• In a Lean organization, whose responsibility is safety?
• Which of the following is considered value-added work?
• Which term represents the fundamental Lean concept that drives improvements by eliminating non-value-added activities?