Organizational Goals and Lean Principles in the Organization

Question 1

A process that is considered best in class will
operate at 6 sigma

Answer 1

False

Question 2

Deming believed that organizations should move

away from numerical quotas and numerical goals for management.

Answer 2

True

Question 3

The original Six Sigma methodology consisted of
all phases except

Measure
Analyze
Control
Define

Answer 3

Define

Question 4

Cost reduction projects can result in all except

Lower product lifetime
Customer defections
Pleased customers
Lower reliability

Answer 4

Pleased customers

Question 5

In the control phase of DMAIC, our prime
objective is to

Develop the solution
Implement the solution
Ensure the problem stays fixed
Close the project

Answer 5

Ensure the problem stays fixed

Question 6

Six sigma can reduce the number of botched
surgical procedures from 5000 every week to

1.7 botched procedures every month
3.4 botched procedures every week
833 botched procedures every week
1.7 botched procedures every week

Answer 6

1.7 botched procedures every week
*Six Sigma quality performance means 3.4
defects per million opportunities

Question 7

Before analyzing and improving a process, we
must first ensure

The process is stable
Management knows what we are doing
We know how much money we will save
Who is responsible for the issue

Answer 7

The process is stable

Question 8

The father of quality engineering is

There is no father of quality engineering
Deming - plan–do–check–act (PDCA) cycle
Juran - Pareto principle (80/20)
Taguchi

Answer 8

Deming
Juran
Taguchi (Correct)

Question 9

The six sigma methodology was first advanced by

Harry and Lloyd
Siegel and Shuster
Harry and Smith
Simon and Garfunkel

Answer 9

Harry and Smith

Question 10

An important step in developing a process flow
is

Walking the process
Creating a work instruction
Making the scope as inclusive as possible
Creating the perfect flowchart the first time

Answer 10

Creating the perfect flowchart the first time

Question 11

After WWII, Japanese manufacturers develop their

philosophy, drawing on the ideas of Deming, Juran, and Henry Ford.

Answer 11

True

Question 12

Lean is a collection of tools, from which you

can pick and choose the ones you like.

Answer 12

False

*Lean tool = process control

Question 13

When documenting the value stream, what are the
boundaries?

From the receiving dock to the shipping dock
It may vary depending on the company
From suppliers’ suppliers to customers’ customers
From direct suppliers to direct customers

Answer 13

From suppliers’ suppliers to customers’ customers
*A value stream is the series of activities that an organization performs, such as order, design, produce, and deliver products and services.8

Question 14

Large batch sizes are generally more efficient.

Answer 14

False

Question 15

Gembas refers to:

The Real Place
Policy Deployment
Work Leveling
Autonimation

Answer 15

The Real Place

Question 16

In a Lean system, any employee has the authority

to stop production if a quality problem is seen

Answer 16

True

Question 17

When applying Theory of Constraints, the most

important thing is managing the bottleneck.

Answer 17

True

Question 18

Which of the following is a tool for workplace
organization

5S
TPM - Total Productive Maintenance
Andon - Signal
SMED - Single-Minute Exchange of Dies (Cycle time deduction)

Answer 18

5S (correct)
TPM
Andon
SMED

Question 19

Which of the following enables an organization
to quickly change from one part number to another?

5S
Andon
TPM
SMED

Answer 19

SMED

Question 20

If a process has availability of 0.95,
performance of 0.96, and quality of 0.94, what is the OEE (Overall Equipment Effectiveness)?

0. 96
1. 94
2. 95
3. 86

Answer 20

0.86
*OEE = Availability (Available hours) × Performance efficiency
(Proportion of production flow to operating time) ×
Rate of quality products (output) (Percentage yield of acceptable
products to total units produced)