Value stream mapping is:

1. A pictorial view that identifies process steps

2. A graphical flow charting technique that shows material and information flows *

3. An identification of inputs, tasks, and outputs

4. A flow charting technique

When the term pull is used in lean thinking, who is ultimately doing the pulling?

1. Downstream operations

2. The taki time

3. Customer *

4. The cycle time

An Ishikawa diagram is also known as

Which of the following 5S stages is primarily the responsibility of top management?

1. Sustain

2. Straighten

3. Shine

4. Sort

If one were to summarize in one word the ground breaking work of Womack, introducing the term lean production to the western world, that word would be:

Which of these is not part of the six sigma mantra?

1. Processes must be improved

2. Processes must be in place

3. Processes must be in control statistically

4. Processes must be ISO 9000 documented

Which of the following is NOT a typical measure of six sigma improvement?

1. Customer complaint increases *

2. Accuracy

3. Return on investment

4. Cycle time reduction

Between plus and minus two standard deviations we expect to find approximately what percent of all the values? About 95 percent *

Where do specification limits come from?

A skilled team facilitator will:

1. Take sides when one side is correct

2. Make sure all opinions are heard

3. Dominate group discussions

4. Correct the group when their ideas are wrong

A team sponsor or champion typically

1. Is a liaison between the team and upper management

2. Fulfills the facilitator role

3. Directs the team on implementing solutions

4. Attends all team meetings

Which one of the following best characterizes the Lean Enterprise Culture?

1. Atmosphere of harmony

2. Faster, better, cheaper

3. High rate production

4. Employees continually improve processes and skills

What is the "set in order" step of 5S?

Which of the following are not standard work charts?

1. Work instructions

2. Customer satisfaction survey report *

3. Safety documentation

4. Work cell layout design

Which of the following is NOT a goal of 5S? Review Later

1. Create an organized workplace

2. Lose less time in searching for tools

3. Provide a means for employees to be able to conduct self inspection

4. Encourage a standard way of operating *

Which of the following is true for the "standardize" step of 5S?

1. Provide encouragement and incentives for everyone to maintain the workplace and follow the rules agreed by the team

2. Remove all unnecessary stuff that is not needed in your immediate work area to conduct operations

3. Create rules for team members to follow in the work area *

4. Clean and inspect your equipment for abnormal wear or conditions that will lead to equipment failure

This type of layout improves communication and visual management (visual management)

1. L-shaped

2. U-shaped *

3. Functional

4. Straight line

Which of the following is the best example of a Poka Yoke application?

1. Square peg in a round hole

2. Motion detector

3. On/Off switch

4. Color codes *

What is kaizen?

1. A product improvement process

2. A process of making small changes for making operations better *

3. Process of rearranging machines to maximize throughput

4. A motivational speech

Which of the following is NOT a role for the team leader?

1. Direct team activities

2. Assess strengths and weaknesses of team members and provide them feedback

3. Gather information about the event *

4. Collect event results with the team

A Cpk of 1.4 means

1. The process can more than meet specifications *

2. The process is not capable of meeting specifications

3. The process is just capable of meeting specifications *

4. The process is almost at the six sigma level of performance

By definition a capable process is one that is operating at the so called __ sigma level

1. Six

2. Three*

3. One

4. Two

Process capability measures should be calculated only

1. When the process is in a state of statistical control*

2. After 3 months of error free operation

3. When we want to know how we are doing

4. When the shape of a histogram is exponential

According to Michael Herry, the factor that differentiates six sigma from other methodologies is

1. It is by project improvement *

2. It translates improvement into financial measures

3. More statistics are used

4. It is based in the Greek philosophy

Which of the following is NOT included in the Six Sigma Road Map?

1. Identify what the customer wants and needs

2. Use quality circles to improve morale *

3. Identify what the customer wants and needs

4. Use a problem-solving methodology

The six sigma approach does all the following except

1. Uses statistics solely as tools for interpreting and clarifying data

2. Requires not just statistics but cultural change

3. Requires no commitment from the highest levels of management *

4. Requires a tolerance for endlessly questioning conventional organizational wisdom

Specification limits come from

1. The customer *

2. Thin air

3. Engineering

4. Inherent process variation

The healthcare challenge includes

1. Weak medical disciplines

2. Clarity about support value streams in complex facilities

3. Strong management tradition

4. Confusion about the customer and value

Positive outcomes of improved healthcare processes include all of the following except Review Later

1. Higher employee involvement and satisfaction

2. Improved patient throughput

3. Longer waits for effective care *

4. Reduced LOS

A poka yoke device detects an error and stops the process. What should the operator do next? Review Later

1. Find the root cause of the problem and carry out corrective action

2. Stop the process, assemble a team, and plan a kaizen event

3. If the problem persists, implement process inspection as a precaution

4. Throw out the defective piece and continue with normal operations

Kanban concepts include all of the following except Review Later

1. JIT

2. Pull instead of push

3. One piece flow

4. Storage in the warehouse but not on the production floor

A company has just started a lean six sigma initiative. Which set of tools would be better suited for initial projects? Review Later

1. Six sigma tools because they provide more data

2. Lean tools because they provide stability and repeatability for future projects **

3. Lean tools because they provide a more reliable and accurate picture of the root cause

4. Six sigma tools because they provide a larger number of available options

In a nutshell, LSS is considered Review Later

1. A business improvement approach or strategy *

2. An elimination of mistakes and defects

3. A concentrated focus on business outputs

4. A focus on critical customer items

Control limits come from

1. Customer expectations

2. Common cause process variation *

3. Supplier capability

4. Engineering specifications

The most important analytical question to ask when using a flow chart is

1. Who

2. Where

3. Why *

4. When

RPN stands for

1. Relative priority number

2. Risk priority number *

3. Reciprocal priority number

4. Risk probability number

Which of the following is NOT true for VSM?

1. A VSM consists of two maps: a current or baseline state map, and a future or envisioned better state map

2. It is usually conducted on the shop floor using pencil and a ledger-sized paper

3. A VSM is drawn to capture the process, starting with the customer requirements and ending with production activities

4. A VSM is a good tool for doing root cause analysis for production delays

The two types of variation that are important in Six Sigma are:

1. Special, Variable

2. Special, Common *

3. Common, Variable

4. Common, Random

Which of the following is true for the "set in order" step of 5S?

1. Develop a sketch of the work area showing where all equipment and tools are located

2. Provide encouragement and incentives for everyone to maintain the workplace and follow the rules agreed by the team

3. Remove all unnecessary stuff that is not needed in your immediate work area to conduct operations*

4. Create rules for team members to follow in the work area