TEST QUESTION PAPER

SET-1

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

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
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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 judgements autonomously at the lowest
possible levels.
d. Allow employees to make judgements 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
16 Lean is being implemented at HAL to:
a. Reduce waste
b. Improve work process
c. Improve Lead time and /or Cycle time
d. Improve safety/Quality
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17 Match the following:
1. Waste of waiting a. Waiting for decision to load the component.
2. Waste of excess inventory b. Std WIP is 75, actual is 250
3. Waste of over processing c. Required Ra value is 1.6, Actual is 0.8 Ra
4. Waste of Transporting d. Moving products between working
18 Choose the correct meaning and example
1. Muda a. Waste I. Rejection
2. Muri b. Strain/Overloading II. Running machine beyond
design RPM
3. Mura c. Variation/Inconsistency III. Maximum Production in
month ends.
19 Match the five S's in Japanese and English:
S1. a. Seiri I. Sort
S2. b. Seiton II. Simplify
S3. c. Seiso III. Sweep
S4. d. Seiketsu IV. Standardize
S5. e. Shitsuke V. Self discipline
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 worksheet
3. Standard operation procedure
4. Standard work in progress
5. Standard work combination sheet
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
 TEST QUESTION PAPER
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 rejection
7. People Movement
25 Select "open-ended" questions you can ask during a voice of the Customer
interview:
1. Can you brief us about 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 requirement?
26 Identify which of the following are documenting reality tools
a. S 1 (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
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
 TEST QUESTION PAPER
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
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 operation 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
 TEST QUESTION PAPER
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. Jodoka
8. Voice of the customer
9. LDMS

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 l loaded backward.
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 the that correctly describes" Kanban" for which TPS is famous :
a. It is similar to electronic signboard 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 card used in
supermarkets.
d. None of the above.
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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 machine are fully loaded
and working even if some operators are not fully loaded:
a. True
b. False

44 Is measurement of product cost a driver measure?

a. Yes
b. No
Give reasons for your answer.? Driver by very name has to drive to achieve the
results. Cost is due to Inventory, Non conformances, OT, Overheads, Energy
manpower etc. These are the Driver measures for cost. By managing these one can
reduce the cost.
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 Why 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
 TEST QUESTION PAPER
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)

49 Identify Muda, Mura and Muri for the following.

a) Operator has to bend for cleaning. - Muda, Muri
b) Operator has to move to stores for bringing tool. - Muda
c) Machine speed is running @ 3000rpm instead of 2000rpm recommended by
machine Manufacturer. - Muri
d) One shift production is more other shift is less. - Mura
e) Quality rate is not consistent. - Mura
f) Truck capacity is 3 tones but is loaded with 6 tones. - Muri
g) Rejection due to quality. - Muda
h) Machine running OK only in first shift. Mura

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
vehicle sold in the producing country.
c) Expertise for commercializing vehicles by utilizing local parts and labour force.
d) All of the above.
 TEST QUESTION PAPER
SET-2

1 TPS stands for : T- Toyota P- Production S- System 3

2 The two pillars of TPS are : 2

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 : 2
a. True
b. False

4 The Seven Wastes are : 7

 Bad Quality
 Motion
 Over Production
 Transport
 Over Processing
 Over inventory
 Waiting

5 What are Muda, Mura and Muri ? 6

Muda is Waste
Mura is Inconsistancy
Muri is Strain

6 A Value Stream Map describes two flows. They are: 2

Material Flow and Information flow

7 List the five S 's' in either Japanese or English : 5

S 1 : Sorting
S 2 : Systematizing
S 3 : Shining
 TEST QUESTION PAPER
S 4 : Standardizing
S 5 : Self discipline /Sustain

Takt time stands for :

8 Available production time in a week divided by no. of pieces demanded by customer. 2

To enable single - piece flow, the cycle time of each operation must by slightly greater than
9 the takt time: 2
a. True
b. False
What are three documents which define standard work :
10 Standard work sheet 3
Standard work combined sheet
Load percentage chart
From a Process Map made during a Kaizen Event, what are the summary data
11 you can get : 6
1. Cycle time and lead time
2. No. of hands off
3. WIP

From a Standard Work Sheet made during a Kaizen Event, what are the summary data you
12 can get : 4
1. Man Movement
2. Material Movement
3. Document Movement
4. Free Space Percentage
Give examples of open - ended " Questions you can ask during a voice of the customer
13 interview : 4
What is your problem, What do you expect from me, How may I help you, What will be
result if you do not supply the material in time etc.

Value adding time is the time spent in converting the form , fit or function of raw material in
14 the direction the customer is willing to pay for : 2

a. True
b. False

15 The typical ratio of value - adding - time to non value - adding for a process which has not 2
undergone Kaizen is : 1:40

16 SMED stands for : S- Single M- Minute E- Exchange D- Die 4

 TEST QUESTION PAPER
17 One of the principles of SMED is changing the internal time to external time, Internal time is 2
the time taken for changeover activities when the machine is stopped :
a. True
b. False

18 The four chart displayed in a Lean daily Management system are: 4

1. Daily Plan
2. Clock Chart
3. Previous day result
4. To do List

19 The three faces of a Policy Deployment Matrix are : 3

1. Goal
2. Measures
3. Action

20 PDPR stands for : P- Policy D- Deployment P- Progress R- Review 4

21 Give an example of a Visual Control : 2

 Clock Chart
 Gantt Chart
 LDMS

22 Write down the names of ten TPS tools that you use in the implementation part of Kaizen 10
Events:
1. 5 'S
2. T.P.M
3. Make it ugly
4. PDM
5. Single piece flow
6. MRS
7. Problem Solving
8. Line Stop
9. 5 Why's
10. Right sizing

23 Describe the function of the " pacemaker " in a cell : 2

Pace maker is used to control takt time. It is also used to distribute production Mix
 TEST QUESTION PAPER
evenly over a period of time.

24 TPM stands for : T- Total P- Productive M- Maintenance 3

25 A Kanban is used to : 2
Send the signal from customer to supplier to supply material

26 In a Lean organization , It is more important to ensure that all machines are fully loaded and 2
working even if some operators are not fully loaded :
a. True
b. False

27 Is measurement of product cost a driver measure? 2

a. Yes
b. No
Give reason for your answer: Cost is not a driver measure, because the driver by the
very name has to drive to achieve the results. Cost is due to Inventory,
Nonconformance, OT, Overhead, Energy, Manpower etc., They are the driver
measures. By managing these one can manage & reduce costs.

28 What are the four steps of the Continuous Improvement Circle : 4

Standardize
 Visual Control
 To know route cause by 5 Why's
 To revise standards and make corrective action.

29 In a TPM Event , the Preventive TO -DO List is made from the fix TO-DO List after the 2
following step : Knowing route cause by 5 Why's

30 Production Leveling is achieved with the help of appropriate inventory carried at defined 2
places in the Value Stream.
a. True
b. False