HAL MANAGEMENT Name:____________________

ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

Test Question Paper

1 TPS stands for:

1. Total Production System
2. Total People System
3. Toyota Production System
4. Both 1 and 2
2 The two pillars of TPS are:
1. Just-in-time and Jidoka
2. Quality and Productivity
3. Reduce Space and Lead Time
4. All of the above
3 TPS focuses on local efficiencies to improve the efficiency of the overall system:
a. True
b. False
4 In TPS, the output of an ideal person, group of people, or machine is produced:
a. Without waste
b. Before the customer desires it
c. With more features than desired
d. In small batches
5 Lean focuses on
a. Eliminating People
b. Improving the Production
c. Improving Machine Capacity Utilization
d. Eliminating Waste
6 Implementing Lean Manufacturing will require huge investments in capital:
a. True
b. False
7 A Production Cell should be configured for flexible demand:
a. True
b. False
8 Lean Manufacturing Techniques apply to Accounts Payable and Payroll:
a. True
b. False

Page 1 of 9
 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

9 Implementation of Lean Manufacturing should only be started in a stable

organization that is experiencing imminent crisis:
a. True
b. False
10 If we implement Lean Manufacturing we can cut our workforce, and thus our
payroll, in half:
a. True
b. False
11 Instructing employees to “work smarter, not harder” and to “eliminate non-value-
added activities” doesn’t work:
a. True
b. False
12 A Lean business organization will strive to:
a. Encourage autonomous decision-making only if the decision has financial
implications.
b. Prevent autonomous decision-making if the decision has financial
implications.
c. Allow employees to make judgments autonomously at the lowest possible
levels.
d. Allow employees to make judgments autonomously only at the highest
levels.
13 Some are reluctant to adopt Lean Manufacturing principles because it would
require that they relinquish much of their decision-making responsibilities to
employees at lower levels:
a. True
b. False
14 A Value Stream Map describes
1. Material Flow
2. Information Flow
3. People Flow
4. Both 1 & 2
5. None of the above
15 Critical information necessary to begin any value stream improvement effort is
with:
a. The manufacturing floor
b. The supplier’s capability
c. Production control
d. The customer requirements

Page 2 of 9
 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

16 Lean is being implemented at HAL to:

a. Reduce Waste
b. Improve Work Processes
c. Improve Lead Time and/or Cycle Time
d. Improve Safety / Quality
17 Match the Following:
1. Waste of Waiting a. Required Ra Value is 1.6, Actual is 0.8 Ra
2. Waste of Excess Inventory b. Waiting for decision to load the component
3. Waste of Over processing c. Moving products between working
4. Waste of Transporting d. Std WIP is 75, Actual is 250
e. Moving Products between process

18 Choose the correct meaning and example

1. Muda a. Variation / Inconsistency I. Rejections
2. Muri b. Waste II. Running Machine beyond design RPM
3. Mura c. Strain / Overloading III. Maximum Production in month ends
19 Match the five S’s in Japanese and English:
S1: a. Shitsuke 1. Simplify
S2: b. Seiso 2. Self Descipline
S3: c. Seiketsu 3. Sort
S4: d. Seiton 4. Sweep
S5: e. Seiri 5. Standardize
20 Takt time is:
1. Interval of time between each unit being completed by a process
2. Interval of time between the start of I step and end of the last in a
product’s process
3. Interval of time between each unit consumed by the customer
4. None of the above
21 To enable single-piece flow, the cycle time of each operation must be slightly
lower (say 95%) than the takt time:
a. True
b. False
22 Choose the three documents which define Standard Work:
1. Percent Load Chart / Process capacity table
2. Standard work sheet
3. Standard operation procedure
4. Standard work in progress
5. Standard work combination sheet

Page 3 of 9
 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

23 Choose the three summary data from a Process Map made during a Kaizen
Event:
1. CT Vs LT Ratio
2. Percent free space
3. Total WIP
4. Document Movement
5. Number of Handoffs
6. % of rejections
24 Choose the summary data we get from a Standard Work Sheet made during a
Kaizen Event:
1. Part Movement
2. Percent free space
3. Total WIP
4. Document Movement
5. Number of Handoffs
6. % of rejections
7. People Movement
25 Select “open-ended” questions you can ask during a Voice of the Customer
interview:
1. Can you brief us about the Problems you are facing?
2. Do you want model A or Model B?
3. What are your expectations?
4. Are you getting the right information?
5. What kind of products you want?
6. What is your daily requirements?
26 Identify which of the following are documenting reality tools
a. S1 (Sorting)
b. Time Observation
c. Why? Why? Analysis
d. Voice of customer
e. Preparing Post-Event Standard Work Sheet
f. Identifying Abnormalities in the machine
g. Mistake Proofing
h. Problem Solving
27 Value-adding time is the time spent in converting the form, fit or function of raw
material in the direction the customer is willing to pay for:
a. True
b. False

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 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

28 The Shape of a Cell is

1. Line
2. U
3. V
4. L
5. Any of the above
29 SMED Means
1. Changeover time less than a Minute
2. Changeover time less than or equal to 9 minutes
3. Changeover time in one touch
4. None of the above
30 One of the principles of SMED is changing the internal time to external time.
Internal time is the time taken for changeover activities when the machine is
stopped:
a. True
b. False
31 The four charts displayed in a Lean Daily Management System are:
1. Mechanical Andon
2. Clock Chart
3. To do List
4. Preventive Check list
5. Daily PDPR
6. Pre-control Chart
7. Multi-Vari Chart
8. Daily Plan
32 The three faces of a Policy Deployment Matrix are:
1. Daily PDPR
2. Goals
3. Actions
4. Action Plan
5. Measures

Page 5 of 9
 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

33 Right Sizing is:

a. Process equipment that is highly capable, easy to maintain
b. Quick to changeover, easy to move
c. designed to be installed in small increments of capacity to facilitate
capital and labour linearity
d. All the above
e. Only a) and c) above

34 Select the answer which correctly describes an “andon” which is used in Toyota
plants:
a. Andon is a check-sheet provided for “visual control”.
b. Andon is a special spot light created to ensure safe operations inside a
plant.
c. Andon is a colour-coded display board that communicates machine
abnormalities to the operation manager or supervisor.
d. None of the above.
35 Choose the Visual Controls:
1. LDMS
2. Production Plan
3. SOP
4. 5 S Checklist
5. Plan Vs Actual Chart
6. Colour Coding of trays
7. Warning Signs
36 Identify TPS tools that you could use in the implementation phase of Kaizen
Events:
1. Visual Controls
2. SMED
3. Standard Work Sheet
4. PDPR
5. Creativity before capital
6. Mistake Proofing
7. Jidoka
8. Voice of the Customer
9. LDMS

Page 6 of 9
 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

37 An example of error-proofing (Poka-yoke) is:

a. Assigning operators to operate more than one machine.
b. Counseling employees who produced defective products.
c. A device that prevents the part from being loaded backwards.
d. Inspecting parts for errors at final assembly.
38 OEE is a measure of
1. Availability
2. Quality rate
3. Performance
4. All the above
None of the above
39 TPM stands for:
1. Total People Movement
2. Total Productive Maintenance
3. Total Product Movement
4. Total Product Manufacturing
40 In TPM, the OEE is calculated for
a. Equipment / Machinery
b. Production Line / cell
c. Any Utility
d. All the above
41 Select the answer that correctly describes “kanban” for which TPS is famous:
a. It is similar to electronic signboards located inside plants, indicating work
being performed.
b. It is an ID card worn by an operator indicating the work to be performed.
c. It is an adaptation of the concept of product control cards used in
supermarkets.
d. None of the above.
42 A kanban is used to:
1. Signal the needs the next process
2. Signal needs to the PPC
3. Signal the needs to the previous process
4. None of the above
43 In a Lean organization, it is more important to ensure that all machines are fully
loaded and working even if some operators are not fully loaded:
a. True
b. False

Page 7 of 9
 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

44 Is measurement of product cost a driver measure?

a. Yes
b. No
Give reasons for your answer: ______________________________________
_______________________________________________________________
_______________________________________________________________
45 Choose the four steps of the Continuous Improvement Circle:
1. Make a Plan
2. Establish the standardize way of working
3. Follow the Plan
4. Visual controls to show any abnormality in following the standard
5. Implement the Plan
6. Ask the 5 Whys to establish why the standard is not followed
7. Implement corrective actions to resolve the root cause of the abnormality
46 Waste elimination is done by
a. Shop Floor People
b. In Design & Office staff
c. Top Management
d. Everyone in the company
47 5 Why’s are used to
a. Find out who did the mistake
b. Find out the root cause for a problem to prevent re-occurrence of the
problem
c. To take a temporary countermeasure
d. All of the above
48 Lean is suitable for
a. Mass & Batch Production
b. Continuous Process Production
c. Custom oriented Job order production
d. All of (a), (b), (c)
e. None of (a), (b), (c)

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 HAL MANAGEMENT Name:____________________
ACADEMY Division:__________________
LEAN MANAGEMENT
PRE-TEST ADVANCED PROGRAM Grade:__________

49 Identify Muda, Mura and Muri for the following

a. Operator has to bend for cleaning
b. Operator has to move to stores for bringing tool
c. Machine speed is running @3000rpm instead of 2000rpm recommended
by Machine Manufacturer
d. One shift production is more other shift is less
e. Quality rate is not consistent
f. Truck capacity is 3 tonnes but is loaded with 6 tonnes
g. Rejections due to quality
h. Machine running OK only in First shift
50 What does “genchi genbutsu” mean in the context of the Toyota Production
System:
a. The belief that you must actually go and see a given situation in order to
really understand it.
b. Work is performed at plants in various countries world-wide with the
finished vehicles sold in the producing country.
c. Expertise for commercializing vehicles by utilizing local parts and labour
force.
d. All of the above.

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