Sample Questions Lean-IT Foundation 2014 465 q+a

Robert Wiering, BSc

SAMPLE QUESTIONS LEAN-IT

FOUNDATION 2014

465 Q+A

FOREWORD{ {

The Lean-IT Foundation exams from APMG ® and EXIN ® are replaced by the Lean IT Foundation exam from the LEAN IT ASSOCIATION.

The Lean-IT Foundation exams from APMG ® and EXIN ® were based on:

• EXIN Lean IT Workbook edition December 2014 Johannes W. van den Bent• Lean IT: Enabling and Sustaining Your Lean Transformation Steven C. Bell and Mi-

chael A. Orzen, 2010• Lean Thinking, Womack & Jones, 1996, Free Press (primary literature, ONLY page 1 to 80)• The Complete Lean Enterprise, Keyte & Locher, 2004, Productivity Press• Toyota Production System, Ohno, 1978, Productivity Press• The Machine That Changed The World, Womack, Jones & Roos, 1991, Harper Perennial• Kaizen, Imai, 1986, The Kaizen Institute

The Lean IT Foundation exam from the LEAN IT ASSOCIATION is based on:

• Lean IT Foundation Publication and Glossary, Niels Loader, Jeroen Janssen• Lean Six Sigma Pocket Toolbook (chapters 1-4, 9), Michael L. George et al• Lean IT, Enabling and sustaining Your Lean Transformation, Steven C. Bell and Mi-

chael A. Orzen• This is Lean, Niklas Modig & Pär Åhlstrom, Rheologica Publishing• The Toyota Way, Jeffrey K. Liker, McGraw Hill• Creating a Lean Culture, David Mann

Because “Lean IT” from Bell & Orzen is used in the new exam the following questions can still be used.

This publication contains 486 questions. 21 are open questions (without answers) and 465 are multi-ple choice (with answers). 2 Tables are used and 45 illustrations.

Robert Wiering, BScCertified Professional Business Process Management & IT

SAMPLE QUESTIONS LEAN-IT FOUNDATION

2014 465 Q+A

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1. Lean systems try to:

a. Produce product in anticipation of demand.b. Maximize the value added by of each of their activities.c. Organize production in large lots to minimize the number of setups.d. Reduce the labor content in all processes.

2. The Toyota Production System principle requires that:

a. Goods and services flow to the next available person.b. Goods and services flow to the next available machine.c. All production lot sizes are exactly one.d. Employees actually doing the work must be actively involved making the improvements in that work.

3. The just-in-time (JIT) system is a(n):

a. Management system of people and procedures to fulfill all delivery deadlines. b. Production system of small-lot manufacturing to reduce work-in-process inventory. c. Materials management system for removing all inventories. d. Integrated system of managing resources, information, and decision processes to eliminate waste.

4. The lean system concept will not work without the proper environment. Which one of the following characteristics is most com-

mon to firms that have successfully implemented a lean system?

a. Uniform assembly schedules.b. Specialized workforce.c. High rates of machine failures.d. Longer setup times.

5. There are many requirements for the successful implementation of the lean system of production. Which one of the following is NOT such a requirement?

a. Uniform assembly schedule.b. Short setup time. c. Low machine failure and low defects.d. Substantial natural resources.

6. Lean systems maintain inventory in small lot sizes because small lot sizes:

a. Increase pipeline inventory, allowing the organization to buffer against demand uncertainties. b. Increase the quality level of the product. c. Enable schedules to use machine capacities more efficiently. d. Increase manufacturing lead-time because of the increase in waiting time.

7. Lean systems use the standardization of components because standardization:

a. Decreases the demand for each component. b. Increases worker productivity. c. Allows for small lot sizes more easily. d. Decreases repeatability.

8. Mistake-proofing is known by the term:

a. Andon.b. Muda.c. Jidoka.d. Poka-yoke.

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9. In lean systems, if a defective product is found, which of the following is generally NOT done?

a. The production line is stopped. b. The defective unit is passed on to the next workstation. c. The defective unit is returned to the worker responsible for creating the defect. d. The production line is made aware of the problem without stopping the line.

10. Companies using lean systems generally have:

a. Many suppliers to ensure that material shortages never occur. b. Suppliers that are located nearby to decrease delivery lead-time. c. Suppliers that are willing to accept short-term contracts. d. Suppliers who are low-cost producers.

11. Which of these activities is NOT part of a 5S program?

a. Sustain.b. Synchronize.c. Standardize.d. Straighten.

12. Continuous improvement with lean systems:

a. Involves navigating a ship over treacherous rocks. b. Requires periodically increasing lot sizes or workforce levels to uncover problems. c. Entails systematically stressing the system and focusing on problem areas. d. Focuses exclusively on internal operations because the logistics department addresses relationships with customers and suppliers.

13. Which one of the following statements regarding the Toyota lean system is TRUE?

a. It is particularly well suited for making irregularly used parts and customized “specials.” b. It is a “push system,” with orders pushed out in anticipation of future requirements. c. Each container has either a withdrawal or production-ordering Kanban. d. The single most important factor in shaping the environment is having reliable suppliers nearby.

14. A Kanban system is an important mechanism for lean system management. Which one of the following statements regarding the operation of a Kanban system is TRUE?

a. A typical Kanban used in the JIT system includes information such as item number, unit price, competitor’s product name, and its price.

b. A Kanban can be used to set the order quantity but NOT the inventory level. c. A Kanban and a container move as a pair once production begins at the fabrication process. d. An empty container can be exchanged for a full container at the storage location even though no Kanban is on the full container.

15. Which of the following maps is NOT a part of value stream mapping analysis?

a. Steady state.b. Current state.c. Future state.d. Work plan and implementation.

16. Which one of the following is an advantage of lean systems?

a. Lean systems reduce equipment needs by using larger lot sizes. b. Lean systems can be implemented in any production environment. c. Lean systems result in a decrease in safety stock and work-in-process inventory. d. Lean systems result in an increase in manufacturing lead times.

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17. Implementing a lean system:

a. Has the advantage that workers have less stress because of the routine, repetitive work they perform. b. Typically relieves the workers and first-line supervisors from activities such as scheduling, expediting, and productivity improvements. c. Requires an examination of the reward system to make sure it is consistent with the JIT philosophy. d. Involves the reorganization of material flows to that of a flexible flow.

18. Which of the following is a process consideration in the implementation of a lean system?

a. Firms might have to change existing layouts.b. Workstations typically will be moved farther apart.c. A contract with strict job classifications will be adopted.d. Plant access by rail will be necessary.

19. Which of the following is NOT a typical concern for inventory and scheduling when implementing a lean system?

a. Frequent, small shipment must be arranged with suppliers.b. Changeover times must be reduced.c. Production schedules must be stabilized.d. Companies can increase setup times because deliveries are frequent.

20. What is the difference between the “push” and “pull” methods of material flow? Which does lean systems use?

21. With respect to lean systems, what is the advantage of standardized components?

22. What are the organizational issues companies must address before implementing a lean system?

23. What are the major characteristics of a lean system?

24. What is Kanban?

25. What is value stream mapping? Briefly outline the steps to be followed in evaluating and improving a process using value stream mapping.

26. What are the four underlying principles of the Toyota Production System?

27. List and briefly define the eight types of waste (or Muda) that often occur in firms, which must be eliminated in implementing lean systems.

28. What are the supply chain implications of the lean system emphasis on close supplier ties?

29. List and briefly define the 5S Practices that serve as an enabler and essential foundation of lean systems.

30. In order for value flow analysis to be effective, a team must take which of the following steps first?

a. Define the value stream.b. Eliminate backlogs in the value stream.c. Identify overlapping functions in the value stream.d. Identify specific work practices within the value stream.

31. Considering the Seven Elements of Waste examples of ________________ waste would be relocating inventory to get it out of the way, repeating walking to retrieve necessary parts at a Work Station or having a Shipping Dock located a significant distance from the warehouse.

a. Motion.b. Conveyance. c. Over processing. d. Correction.

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32. The 5S approach to removing waste is part of the application of Lean and is comprised of Sorting, Straightening, Sharpening, Standardizing and Sustaining.

a. True.b. False.

33. A Kanban is used as a part of the ____________________ portion of Lean to assure the proper amount of inventory and appropri-ate timing of inventory flow through a system.

a. Visual Factory.b. Kaizen Event. c. Standardizing. d. Shakowa Analysis.

34. Which of the following techniques is most appropriate for generating continuous improvement ideas?

a. Tree diagram.b. Brainstorming.c. Prioritization matrix.d. Interrelationship digraph.

35. Which of the following tools is most likely to be used to organize a list of ideas generated during a brainstorming session?

a. Activity network diagram.b. Affinity diagram.c. Histogram.d. Process control chart.

36. Kaizen is defined as:

a. Re-engineering.b. Lean manufacturing.c. Continuous improvement.d. Error-proofing.

37. Poka-yoke is best defined as:

a. Improving machine efficiency.b. Reducing field failures to virtually zero.c. Capturing the voice of the customer.d. Preventing controllable defects.

38. Which of the following concepts is mostly associated with Taiichi Ohno?

a. SPC.b. TOC.c. CTQ.d. TPS.

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39. A Belt has used the 5S approach of Lean to set up a control method with frequently used tools organized as shown in this graphic. The Belt has applied the ______________ principle of 5S.

a. Shining.b. Sorting. c. Straightening. d. Sustaining.

40. Producing more than is needed by the next step in the process or more than the customer needs is an example of which of the Se-ven Elements of Waste?

a. Overproduction. b. Correction (defects).c. Inventory. d. Motion.

41. Which of the following is NOT among the five Lean principles?

a. Pull.b. Perfection.c. Optimization.d. Flow.

42. Describe at least two ways in which IT can support Lean manufacturing.

43. The application of the Lean principles is relatively new in IT.

Examples of sources of waste in IT are:- Defects; i.e. caused by unauthorized changes to the infrastructure- Waiting; i.e. by slow responding applications (caused by lack of capacity)- Excess inventory- Repetition of problems (caused by lack of root cause analysis)

Which type of resources can help us to tackle these sources of waste?

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44. Which of the following is NOT one of the fundamental reasons for embarking on a Lean transformation?

a. Higher quality products and/or services.b. Elimination of waste.c. Maximizing company profits.d. Sustained results in terms of improved quality.

45. In a software development process, the activity of testing would in most cases be considered as:

a. A value-adding and necessary activity.b. A value-adding but unnecessary activity.c. A non-value-adding but necessary activity.d. A non-value-adding and unnecessary activity.

46. Which of the following situations would be considered waste in an operations process?

1. PC’s in stock.2. Preventive maintenance on a server.3. The technician enquiring for address information from the customer.4. Completing and storing backups.

a. None.b. 1, 2 and 3.c. 1 and 3.d. All of them.

47. Which of the following percentage of time is spent on value adding activities in a typical process?

a. 0,05b. 0,35c. 0,6d. 1

48. Which technique would NOT be considered a Lean Waste Analysis method?

a. Front-loading.b. 5 Why’s.c. Ohno’s circle.d. Kaizen.

49. Which of the following plays an important part in making value flow?

a. Muri.b. Poka-yoke.c. Kanban.d. Jidoka.

50. Takt in a software development project could be:

1. An alignment of meetings at all levels to allow the shortest amount of waiting time for decisions.2. A fixed agreement on when status meetings are held in the project.3. An agreed process for submitting timesheets and expenses.4. A template for how stakeholder management must be documented.

a. 1 and 2.b. 1 and 3.c. 2, 3 and 4.d. All of them.

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51. Which of the following statements describes front-loading:

1. Better match between the it-systems used in the process, and the competences needed to use them2. Fewer errors and misunderstandings, due to more information and knowledge early in the process3. Critical issues are moved to the top of the agenda on all status meetings4. More involvement of customers in the beginning of the process to ensure less waste

a. 1 and 3.b. 2, 3 and 4.c. 2 and 4.d. All of them.

52. Reducing variance in for instance a server configuration process will most likely result in a better flow of work because of:

1. Higher predictability.2. Better opportunities for the HR department to create career paths.3. More employees will be able to understand the technical details of the process.4. Better ability to man the different activities to match the actual need.

a. 1.b. 1 and 3.c. 1 and 4.d. None.

53. In Lean software development, the pull-system can be implemented in the form of a Kanban-system.

When implementing such a Kanban system, which are the key focus areas?

1. Measure and improve the cycle time (or lead time).2. Set goals for quality and improve it.3. Limit work-in-progress.4. Ensuring that most of the employees are trained in the strategy of the department.

a. 1, 2 and 3.b. 1, 2 and 4.c. 2, 3 and 4.d. All of them.

54. Pull systems have been implemented in software development processes in several places.

Which are some of the reasons for implementing a pull system in a software development process?

1. To have better visibility with what is pulled into any given release.2. To be better able to control the amount of code under development (work-in-progress). Thus controlling the cost and complexity in

the process.3. To ensure visibility for everybody on what is being developed, in what quantities and for which customer.4. To ensure that nothing is developed, without there being an actual demand for it.

a. 3 and 4.b. 2 and 4.c. 1 and 2.d. All of them.

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55. An alternative system for initiating activity in a process is called the pull-system, as used in Toyota.

Which of the following statements BEST describes the triggering of an activity in Toyota:

a. A Kanban card is sent to a work station upstream from the station needing an item, thus triggering the production of the needed item in the desired quantity

b. An employee walks between the different workstations overseeing the process and spotting the need for items in the different worksta-tions

c. The need for an item is entered into a computer system, which calculates a production plan and sends out messages to the different stations on what to produce, and when

d. A workstation may trigger a song to play when an item is needed, thus informing the manager, that he/she needs an item

56. One of the key aspects of a Pull system is the daily scheduling technique.

Which of the following is the scheduling technique used in the Toyota Production System?

a. Heijunka.b. Pokey-yoke.c. Jidoka.d. Kaizen.

57. The Kaizen board manager has responsibilities towards conducting the meetings in the best way possible.

Which of the following statements is NOT part of that responsibility?

a. Ensure that all participants at the meeting are heard.b. Take primary responsibility for the implementation of most of the ideas.c. Encourage more ideas for the board.d. Keep track of the time.

58. Many companies that have implemented Kaizen have implemented it using Kaizen boards and Kaizen meetings.

How often are these regular Kaizen meetings usually held to focus efforts on small improvements?

a. Every hour.b. Every week.c. Every 6 months.d. Every year.

59. Continuous improvement can be either done by small incremental steps or by regular radical changes. In Lean practice experien-ce has taught that both strategies are needed to get good results. The two different approaches are called Kaizen and Kaikaku.

Describe each of these two approaches in your own words.

60. Group oriented Kaizen should be institutionalized as a permanent approach, and is represented in Quality Control (QC) circles (also called Kaizen teams).

Name some forms these (small) group activities can take in an organization.

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61. What would be the next step in the standard work process?

1st Establish2nd Communicate3th Follow4th ?

a. Strengthen.b. Inform.c. Act.d. Improve.

62. Which of the following is the correct definition of Value Stream?

a. A sum-up of the entire value stock of any company.b. All the activities required to bring a specific product through the critical management tasks of any business.c. The process by which a service is added value to its target customers.d. A standard flow of products in a company covering both initial manufacturing and final shipment to the customer.

63. When progressing from a Lean project to a Lean organization, there are several pitfalls to be avoided, in order to have a better chance of success in the long term.

Which of the following are important factors to succeeding in the long term with Lean?

1. Making Lean part of the culture in the company.2. That benefits are actually achieved.3. Focus on continuous improvement.4. Management understanding and support.

a. 2 and 3.b. 1, 2 and 3.c. 3 and 4.d. All of them.

64. Lean needs a Lean Management system using the various Lean tools that help connect the purpose of Lean (creating customer value) to people and processes.

Name at least three core elements that a Lean Management system include:

65. What are the ‘5 Stages of Grief’ in the model by Elisabeth Kubler-Ross?

Place them in the right order.

66. What are the three major styles of leading change?

Give a short description of each style.

67. Change Agent needs to be effective in four critical areas, and able to:

68. What are the five stages in a Lean implementation proposed by Keyte & Locher (2004)?

69. What are typical activities for stage 2. Design the current state?

70. What are typical activities for stage 4. Design the future state?

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71. The 5 stages of grief are:

1. Shock and Denial, Anger, Depression and Detachment, Dialogue and Bargaining, Acceptance.2. Shock, Depression, Anger, Bargaining, Acceptance.3. Anger, Shock and Denial, Depression and Detachment, Dialogue and Bargaining, Acceptance.4. Dialogue and Bargaining, Depression and Detachment, Acceptance, Anger, Shock and Denial.

a. 1 is correct.b. 3 is correct.c. None is correct.d. All are correct.

72. 5S is:

1. The principle of waste elimination through workplace organization.2. Derived from the Japanese words: Seire, Seiton, Seiso, Seiketsu and Shitsuke.3. Safety is the sixth S.4. Sort, Straighten, Scrub, Systematize, Standardize.

a. 1 is correct.b. All of the above are correct.c. 3 is NOT correct.d. 4 is correct.

73. Autonomation is:

1. Automation with a human touch.2. Jidoka.3. Intelligence is added to equipment to prevent the production of defective products, eliminate overproduction, and automatically stop the process when abnormalities are detected.4. This type of automation frees people to perform more valuable activities.

a. 1 and 4 are correct.b. 2 is correct.c. All of the above are correct.d. 3 is NOT correct.

74. Which one is correct?

1. Yokeru = mistake, Jidoka = autonomation, Gemba = the real place.2. Heijunka = level scheduling, Hoshin Kanri = good planning.3. Hoshin Kanri = policy deployment, Kaikaku = incremental improvement.4. Heijunka = level scheduling, Hoshin Kanri = policy deployment.

a. 1 and 4.b. 2 and 3.c. 2 and 4.d. None.

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75. WIP =

1. Work in progress.2. Number of items worked on (in progress) in the process.3. In process inventory.4. Waiting in production.

a. 4 is correct.b. 1 and 2 are correct.c. 1, 2 and 3 are correct.4. All of the above are correct.

76. Waiting:

1. Waiting occurs when products are not being processed or flowing.2. People in a process delayed or stopped because of process waste or ineffective process design.3. Is a form of muri.4. Is the W from Tim Wood.

a. All are correct.b. 1, 2 and 4 are correct.c. 2 and 3 are correct.d. 3 and 4 are correct.

77. A change agent is:

1. A Lean Champion leading the change.2. A manager or executive that is appointed to help facilitate the organizational change process.3. The manager who is responsible for the ITIL change process.4. The chairman of the Change Advisory Board.

a. All are correct.b. None of the above are correct.c. 2 is correct.d. 3 and 4 are correct.

78. Value Stream Map’s:

1. A Current State Map is a Value Stream Map that depicts things, as they currently exist within the value stream.2. A Future State map is a VSM that depicts an improved view of the value stream.3. A technique used to analyze the flow of materials and information required to bring a product or service to a customer.

a. All are correct.b. 1 and 2 are correct.c. 2 and 3 are correct.d. 1 and 3 are correct.

79. Concurrent engineering:

1. Is a work methodology based on the parallelization of tasks.2. It refers to an approach used in product development in which functions of design engineering, manufacturing engineering and other func-tions are integrated to reduce the elapsed time required to bring a new product to the market.

a. Both are wrong.b. 1 is correct.c. 2 is correct.d. Both are correct.

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80. Continual improvement:

1. Is an ongoing process in an organization with the objective to find, resolve and share solutions to problems.2. The objective is to achieve perfection, in other words to improve value streams, product and customer value.3. A philosophy of frequently reviewing processes, and implementing changes to get closer to perfection.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. 1 and 2 are correct.e. 1 and 3 are correct.f. 1, 2 and 3 are correct.

81. A customer is:

1. The person or group of people who use your product or service.2. The person next in line in the value stream.3. The person or entity that is the recipient of what you produce, either within your organization or outside your organization.


82. Customer value:

1. Is the economic worth of a product or service to somebody else: the customer.2. Is a capability provided to a customer at the right time at an appropriate price, as defined by the customer.

a. 1 is correct.b. 2 is correct.c. Both are correct.d. Both are wrong.

83. A Defect is:

1. The output of a process that does not meet requirements.2. One of the seven forms of waste.3. The output of a process that fails to meet the required specification or performance standard.


84. What is the best definition of Flow:

1. Make the value creating steps occur in tight sequence so that the product will flow smoothly towards the customer.2. The movement of a product or service along the value stream, from its inception to the customer.

a. 1.b. 2.

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85. Front-loading is:

1. To assign costs or benefits to the early stages of (as a contract, project, or time period).2. Putting more effort into the early stages of development to ensure a smooth transition to production at the end of product development.

a. 2.b. 1.c. None of the above.d. 1 and 2.

86. Heijunka is:

1. Level scheduling.2. The technique of smoothing or leveling schedules.

a. 1.b. None of the above.c. 2.d. 1 and 2.

87. Hoshin Kanri is best described by:

1. Policy deployment.2. Deployment of Lean in a way that aligns the focus and activity of Lean with the goals and objectives of the organization.3. A system of planning, forms and rules that engages everyone in addressing business at both the strategic and tactical levels.

a. 3.b. 2.c. 1.

88. Jidoka is:

1. Autonomation.2. Automation with a human touch.3. Transference of human intelligence to machines via automation.4. The automation enables the equipment to detect defects and stop until someone comes to fix the problem.5. This supports quality at the source and the prevention of defects from progressing along the value stream.

a. 1 is incorrect.b. None of the above is correct.c. 1, 3 and 5 are correct.d. 2 and 4 are correct.e. All the above are correct.

89. Just In Time:

1. Providing what is needed, when it is needed, in the quantity needed and in the quality needed.2. A system for producing and delivering the right items at the right time in the right amounts.3. JIT approaches just-on-time when upstream activities occur minutes before down-stream activities, so single piece flow is possible.4. The key elements of JIT are flow, pull, standard work (with in process inventories) and takt time.

a. 1 is correct.b. 1 and 2 are correct.c. 1, 2 and 3 are correct.d. 1, 2, 3 and 4 are correct.

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90. Kaikaku is:

1. Radical improvement activity to reduce waste.2. The opposite of Kaizen.3. Also known as breakthrough kaizen, flow kaizen or system kaizen.

a. 1, 2 and 3 are correct.b. 1 and 2 are correct.c. 1 is correct.d. All of the above are correct.e. None of the above is correct.

91. What is a correct definition of Kaizen:

1. An improvement philosophy in which continuous incremental improvement occurs over a sustained period of time, creating more value and less waste, resulting in increased speed, lower costs and improved quality.2. Incremental continuous improvement that increases the effectiveness of an activity to produce more value with less waste.3. Continuous incremental improvement of an activity to create more value with less muda.4. Continuous incremental improvement.


92. Kanban is:

1. A signal that triggers replenishment or with-drawl in a pull system.2. Kanban is often in the form of a card on a container in production environments.3. The signal regulates the production flow in a push system.4. A Kanban card travels with the inventory, containing information such as the description of the item or part number, and its location.


93. Muda:

1. Muda is the Japanese for overburden.2. Muda is any activity that consumes resources but does not provide value as defined by the customer.3. Muda-type 1 is necessary for process, but ads no value.4. Muda-type 2 is both unnecessary and non-value adding.

a. 1 is wrong, 2 is correct, 3 and 4 are correct.b. 1 and 2 are correct.c. 3 and 4 are correct.d. 1, 2 and 3 are correct.

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94. Mura:

1. Mura is the Japanese for overburden.2. Mura is inconsistency and variation.3. Mura is waste due to unevenness or variation.4. Mura is variation in an operation.

a. All of the above are correct.b. None of the above is correct.c. 2, 3 and 4 are correct.d. 1 is wrong and 4 is also wrong.

95. Visual workplace:

1. A visual workplace is also known as visual factory.2. A visual workplace is also known as visual management.3. Visual workplace helps sustain lean operations by using visual tools to ensure that improvements remain clearly visible, readily understood and consistently adhered to long after the lean event is over.

a. All of the above are correct.b. None of the above is correct.c. 2 and 3 are correct.d. 1 is wrong and 3 is also wrong.

96. Muri:

1. Muri is overburden.2. Muri is waste or stress on the system due to overburdening or unreasonableness.3. Muri is the unnecessary or unreasonable overburdening of people, equipment or systems by demands that exceed capacity.

a. All of the above are correct.b. None of the above is correct.c. 2 and 3 are correct.d. 1 is wrong and 3 is also wrong.

97. Overproduction:

1. Overproduction is producing more than the customer requires.2. Overproduction is one of the seven forms of waste.3. Overproduction causes other wastes like inventory costs.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. 1 and 2 are correct.e. 1, 2 and 3 are correct.f. 2 and 3 are correct.

98. Value stream is best described by:

1. The flow of materials and information through a process to deliver a product or service to a customer.2. The specific activities required to design, order, and provide a specific product or service from the point of product (or service) concept, through launch, ordering raw materials, production and placing the product (or service) in the hands of the customer.

a. 1.b. 2.

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99. What is the best description of perfection?

1. A key objective of Lean to bring a product or service into a state where the number of defects is zero or as close as possible to zero.2. The complete elimination of muda so that all activities along a value stream create value.

a. 2.b. 1.

100. Poka-yoke:

1. Poka-yoke = mistake proofing.2. Poka-yoke = mistake proofing and yokeru = mistake.3. Poka-yoke is a device to prevent defect production.4. Poka-yoke is something in a product, process, or procedure that physically or procedurally prevents you from making a mistake.

a. 1, 3 and 4 are correct.b. All of the above are correct.c. 1, 2 and 3 are correct.d. 1, 2 and 4 are correct.

101. In value added analysis:

1. Activities are divided into high and low value added activities.2. Activities are divided into activities the customer is willing to pay for or not.3. Activities are divided into activities that transform the product or service in some way or not.4. Activities are divided into activities that are done the first time right or not.

a. 2, 3 and 4 describe VAA the best and 1 is correct.b. 2, 3 and 4 describe VAA correct and 1 is NOT correct.c. 1 and 3 are correct.d. 2 and 4 are correct.

102. Pull is a system of cascading production and delivery instructions from downstream to upstream activities in which nothing is produced by the upstream supplier until the downstream customer signals a need.

1. Pull is the opposite of push.2. The definition above is correct.3. Pull is together with customer value, value stream, flow and perfection one of the 5 principles of Lean.

a. 1 is correct.b. 1 and 2 are correct.c. 1, 2 and 3 are correct.d. 2 and 3 are correct.e. 1 and 3 are correct.

103. Standardized work:

1. Is the definition of a process step characterized by takt time, a set work sequence and established in-process inventory.2. Deviations to standardized work constitutes an abnormality, which is an opportunity for improvement.

a. 1 is correct.b. 2 is correct.c. 1 and 2 are correct.d. 1 and 2 are NOT correct.

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104. Takt time:

1. Is English for Taktzeit.2. Is the available production time divided by the rate of customer demand.3. Takt times are noted in the box scores in VSM’s.4. Is one of the five elements of JIT.

a. All of the above are NOT correct.b. 1 and 3 are correct.c. 2 and 4 are correct.d. 1, 2 and 3 are correct.e. All of the above are correct.

105. TPM:

1. Is Total Performance Measurement.2. Is a proactive approach to maintaining equipment.3. Is part of JIT.4. Is part of TPS.

a. All of the above are correct.b. 1 is correct.c. 2 is correct.d. 3 and 4 are correct.e. None of the above is correct.f. 2, 3 and 4 are correct.

106. TPS:

1. TPS = Tested Products Scientifically (with Six Sigma).2. A production system developed by the Toyota Motor Company based on the philosophy that the ideal condition for production is created when machines, facilities and people work together adding value without creating waste.


107. Variance:

1. Is Mura.2. Is variation in an operation, when activities don’t go smoothly or consistently.3. There is variation in quality, cost or delivery.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. 1 and 2 are correct.e. 1 and 3 are correct.f. 2 and 3 are correct.g. 1, 2 and 3 are correct.h. None of the above is correct.

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108. A Shewhart chart:

1. Is a control chart.2. Serves as the basis for determining whether a process is in our out of statistical control.3. Is a graphical display of the value of some process or quality characteristic over time.4. Has control limits: the UCL and LCL.5. Differs from a run chart in having an UCL and LCL.

a. 5 is correct.b. 4 is correct.c. 3 is correct.d. 2 is correct.e. 1 is correct.f. 1, 3 and 5 are correct.g. 2 and 4 are correct.h. All of the above.

109. A Gemba walk:

1. Is an observation tour.2. Is NOT a “run through that area, wave hello, and get back to your office” tour.3. Is used to observe and ask questions about things you notice.4. Is NEVER done with a checklist or items to review.

a. 2 and 4 are correct.b. 1 is correct, 3 is not correct.c. All of the above are correct.d. None of the above is correct.e. 1, 2 and are correct, 4 is not correct.

110. Zero Defects:

1. ZD or zero defect movements are small-group activities to carry out specific tasks in the workshop.2. Meet on a weekly basis.


111. Empowerment:

1. Is one of the three major styles of leading change.2. Do it your way!3. Belongs in the list: Command and Control and Lean Leadership.4. Lacks the rigor of Lean methods or the alignment of purpose.

a. 1 and 2 are correct.b. 3 and 4 are correct.c. 2 and 4 are correct.d. 1 and 3 are correct.e. All of the above are correct.

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112. A change agenda answers the question:

1. Where are we going and why.2. How to get there.

a. 1 is correct.b. 2 is correct.c. Both are correct.d. Neither 1 or 2 are correct.

113. Command and Control:

1. Is one of the four major styles of leading change.2. Is equivalent to: Do it your way.3. Is based on a military command structure.

a. All of the above are wrong.b. 1 is correct.c. 2 is correct.d. 3 is correct.

114. Continuous feedback loops:

1. Ensure that the customer really gets what he/she wants.2. Create less waste and the customer is more satisfied with the product and/or service.


115. Kaizen corners:

1. A space or place in the workshop where Kaizen activities are published and presented.2. Where workers from other areas are invited to study examples and adopt the good practices.

a. Both are wrong.b. Both are correct.c. 1 is correct.d. 2 is correct.

116. There are different types of Kanban cards:

1. Permanent Kanban Cards.2. Single-Use Kanban Cards.3. Permanent Kanban Cards can be divided into: withdrawal Kanban and production Kanban.

a. All of the above are correct.b. None of the above is correct.c. 1 and 2 are correct.d. 1 and 3 are correct.

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117. Group oriented Kaizen:

1. Focuses on systems and procedures.2. Focuses on work within the same workshop/team.3. Focuses on individual work.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. All are wrong.

118. Reasons for embarking on a Lean transformation are clearer in periods:

1. Of crisis or low growth.2. Increasing economic growth.3. When customers have lower demands.4. When prices are reduced.

a. 1 is correct.b. 1, 3 and 4 are correct.c. 2 is correct.d. All are correct.

119. Management oriented Kaizen:

1. Focuses on managers.2. Focuses on work within the workshop/team.3. Focuses on systems and procedures.

a. All are correct.b. All are wrong.c. 1 is correct.d. 2 is correct.e. 3 is correct.

120. Lean tools and techniques are:

1. Kaizen.2. Waste.3. Flow, Pull.4. Kanban.

a. 1 and 3 are correct.b. 2 and 4 are correct.c. None of the above is correct.d. All of the above are correct.

121. Individual oriented Kaizen:

1. Focuses on the individual in systems and procedures.2. Focuses on the role of the individual in the workshop/team.3. Focuses on individual work.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. All are correct.e. 1,2 and 3 are NOT correct.

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122. Core elements of a Lean Management System are:

1. Strategy development, shared performance measures, a visual management system.2. Leader standard work, a problem solving system, leadership development and discipline.3. Leader standard work, shared performance measures, strategy development.4. A visual management system, leadership development and discipline, strategy deployment.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. 4 is correct.e. None of the above is correct.f. All of the above are correct.

123. Benefits of a pull system are:

1. Helps to eliminate stock outs and expediting fees.2. Helps to shorten and control lead times.3. Helps to shorten lead-time with suppliers.4. Increases customer satisfaction.5. Reduces batch or lot sizes.

a. None of the above is correct.b. 1, 3 and 5 are correct.c. 2 and 4 are correct.d. All of the above are correct.

124. When using a Kanban board to manage work in progress, which of the following best summarizes the philosophy behind the approach?a. It is a sign of the work being done and should be maximized to boost performance. b. It is a sign of the work being done and should be limited to boost performance. c. It is a sign of the work queued for quality assurance, which should not count toward velocity. d. It is a sign of the work queued for user acceptance, which should not count toward velocity.

125. The steps involved in value stream analysis include:a. Create a value stream map to document delays and wasted time, such as meetings and coffee breaks. b. Create a value stream map of the current process, identifying steps, queues, delays, and information flows. c. Review the value stream map of the current process and compare it to the goals set forth in the project charter. d. Review how to adjust the value stream charter to be more flexible.

126. Which Agile principle has close resemblance to Lean principle of eliminating waste?

a. Continuous attention to technical excellence and good design enhances agility.b. Simplicity – the art of maximizing the amount of work not done – is essential.c. At regular intervals, the team reflects on how to become more effective, then tunes and adjusts its behavior accordingly. d. Working software is the primary measure of progress.

127. Which one of the following roles are prescribed by the Kanban development method?

a. Product Owner.b. Development team.c. Neither A or B.d. Both A and B.

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128. Which one of the following would NOT be seen as one of the Lean Muda or seven deadly wastes?

a. Partially done work.b. Extra features.c. Relearning.d. Exploratory Testing.

129. What is KanBan? a. A list of activities banned by the team, in relation to Team Norms.b. The set of Can Have stories for a project.c. A visible chart of work to do, work in progress and work done. d. A graph of tasks partially-completed by the team.

130. A visual control used in Lean to represent the velocity of business solutions delivered is:

a. Business Value Delivered Chart.b. Iteration Burn-Down Chart. c. Product Backlog. d. Lean Portfolio.

131. The technique used to analyze the flow of information and materials through a system to eliminate waste is:

a. Fishbone diagram. b. Flow Chart. c. Value stream mapping. d. Pareto Chart.

132. What does the fundamental phrase ‘fast-flexible-flow’ used in Womack & Jones imply?

a. Small batch size, which can provide fast time to market.b. Identify waste and eliminate it.c. Value Stream Analysis. d. Optimize the whole with speed and sustainability.

133. When used in Agile environments what does the term Kaizen refer to?

a. Rhythm.b. Continuous improvement.c. Iteration.d. Empirical processes.

134. In Lean software development decisions SHOULD be made…

a. Well in advance to allow time for estimation and planning.b. Only when sufficient investigation has taken place.c. At the last responsible moment.d. By the senior management only.

135. Which of the following defines the goal of testing in lean agile?

a. Testing is to improve the process and quality. b. Testing play the most crucial role in ensuring the intrinsic quality of the product. c. In lean agile testing always mean Test Driven Development. d. Testing is the primary measure to ensure that we do not have escaped defects.

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136. A diagram, which describes the overall, flow; provides a measurement for every significant step in the workflow is?

a. Kanban board.b. Cumulative Flow diagram. c. Burn Down Chart. d. Parking Lot Chart.

137. What role “product champion” plays in lean agile projects?

a. Makes the decisions about which products to create or enhance. b. The product owner is the “one wring-able neck” for what the product should be. c. It's a role that is responsible for delivery in lean agile. d. One person who is totally accountable for the project outcome.

138. Single-piece flow, pull production was achieved using which method:

a. Scrum. b. Re-Engineering. c. Lean Manufacturing. d. Six Sigma.

139. What are the main seven types of waste?

a. Money, Software, Entertainment, Waiting, Resources, Under-utilized machines, Excess machine capacity. b. Inventory, Storage, Misalignment, Overheating, Electricity, Chatting, Communication. c. Transportation, Inventory, Motion, Waiting, Over-production, Over-processing, Defects. d. Under-utilized resources, Transportation, Inventory, Motion, Waiting, Over-production, Defects.

140. An agile team is planning the tools they will use for the project. They are debating how they should show what work is in pro-gress. Of the following options, which tool are they most likely to select?

a. User story backlog. b. Product roadmap. c. Work breakdown structure. d. Task board.

141. What type of waste is creating extra reports that no one needs?

a. Defect. b. Inventory. c. Over Production. d. Over processing.

142. When using a Kanban board to manage work in progress, which of the following best summarizes the philosophy behind the approach?

a. It is a sign of the work being done and should be maximized to boost performance. b. It is a sign of the work queued for user acceptance, which should not count toward velocity. c. It is a sign of the work being done and should be limited to boost performance. d. It is a sign of the work queued for quality assurance, which should not count toward velocity.

143. What type of waste is “Excessive or unnecessary emails and document get forwarded multiple times”?

a. Over Production. b. Inventory. c. Extra Motion. d. Extra Transportation.

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144. The “5 Whys” technique is used for what purpose?

a. Just-in-time delivery. b. Continuous Improvement. c. Reduce Waste from a process. d. Find out root cause of a problem.

145. Which of these tools / techniques represents “continuous improvement”?

a. Kanban. b. Six Sigma. c. Kaizen. d. Scrum.

146. The steps involved in value stream analysis include: a. Review the value stream map of the current process and compare it to the goals set forth in the project charter. b. Create a value stream map of the current process, identifying steps, queues, delays, and information flows. c. Create a value stream map to document delays and wasted time, such as meetings and coffee breaks. d. Review how to adjust the value stream charter to be more flexible.

147. Which one of these items is not a type of standard set of waste?

a. Over production. b. Taxes. c. Transportation. d. Motion.

148. Plan Do Check Act (PDCA Cycle) was popularized by:

a. Deming. b. Womack. c. Ishikawa. d. Kaizen.

149. What is the name of the process, tool or technique, which help in automatic detection of process malfunction and product defect and prevents it from moving forward in the production process?

a. Kaizen. b. Jidoka (Autonomation).c. Kanban. d. Poka Yoke.

150. At the foundation level of the Lean Enterprise principles Pyramid are:

1. Constancy of Purpose.2. Respect for people.3. Pursuit of Perfection.4. Proactive behavior.

a. All are correct.b. 1, 2 and 3 are correct.c. 4 is correct.d. None of the above is correct.

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151. At the perspective level of the Lean Enterprise principles Pyramid are:

1. Voice of the customer.2. Quality at the Source.3. Systems Thinking.4. Culture.


152. System kaizen:

1. Is also called flow.2. Attempts to improve the overall value stream by enhancing material and information flow.3. Is the focus of management.

a. 1 is correct.b. 2 is correct.c. 3 is correct.d. None of the above is correct.e. All of the above are correct.

153. Process kaizen:

1. Is performed by teams and individuals.2. Concentrates on reducing waste in specific focus areas within the value stream.

a. 1 is correct.b. 2 is correct.c. Both are correct.d. 1 and 2 are wrong.

154. Kaikaku:

1. Is typically initiated by senior leadership.2. Is system kaizen focused on achieving radical improvement.3. Is contrasted with kaizen, which is gradual and continuous.4. Is strategically focused and represents a leap forward, not incremental change.

a. 1 and 3 are correct.b. 2 and 4 are correct.c. None of the above is correct.d. All are correct.

155. The product-process diagonal has 4 manufacturing types:

1. ETO = Engineer to order.2. MTO = Make to order.3. ATO = Assemble to order.4. MTS = Make to stock.

a. 1 and 3 are correct.b. 2 and 4 are correct.c. None of the above is correct.d. All are correct.

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156. The ITIL version 3 service life cycle model consists of five stages:

1. Service strategy.2. Service design.3. Service transition.4. Service operation.5. Continuous service improvement.

a. All are correct.b. 1, 3 and 5 are correct.c. 2 and 4 are correct.d. None of the above is correct.

157. The triple constraints model has the following aspects:

1. Time.2. Resources.3. Cost.4. Management.5. Scope.

a. All are correct.b. None of the above is correct.c. 1, 3 and 5 are correct.d. 2, 4 and 5 are correct.

158. Command and control:

1. Was the established management system between 1890-1940.2. Workers were seen as interchangeable resources.3. Workers were hired for their hands, not their minds.4. Those in management positions solved problems and were paid to think.5. Workers were expected to follow orders and meet output quotas.

a. None of the above is correct.b. All are correct.c. 1, 3 and 5 are correct.d. 2, 4 and 5 are correct.

159. System kaizen is also called flow:

a. True.b. False.

160. A Heijunka box is a physical box that holds physical Kanban cards.

a. True.b. False.

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161. DMAIC stands for:

1. Define.2. Measure.3. Analyze.4. Improve.5. Control.

a. All are correct.b. 1, 3 and 5 are correct.c. 2 and 4 are correct.d. None of the above is correct.

162. ATO means:

1. All tests overdue.2. Assemble to output.3. Assemble to order.

a. None of the above is correct.b. 2 is correct.c. 1 is correct.d. 3 is correct.

163. BPR means:

1. Business process redesign.2. Best practices redesign.3. Best practices reengineering.4. Business process reengineering.


164. BPM means:

1. Business process improvement.2. Best practices interaction.3. Best practices management.4. Business process management.


165. CMM means Capability Maturity Model:

a. False.b. True.

166. ETO means engineer to order:

a. False.b. True.

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167. KPI means key performance indicators:

a. False.b. True.

168. MTO and MTS:

1. MTO = make to order.2. MTO = make to overstock.3. MTS = make to stock.4. MTS = make to supply.

a. None of the above is correct.b. 1 and 3 are correct.c. 2 and 4 are correct.d. 2 and 3 are correct.

169. MRP means material resource planning:

a. False.b. True.

170. MTBF and MTTR are:

1. MTBF = mean time between failures.2. MTTR = mean time to repair.

a. None of the above is correct.b. 1 is correct.c. 2 is correct.d. Both are correct.

171. PDCA means Plan, Do, Check, Act.

a. False.b. True.

172. PMBOK means Project Management Body of Knowledge:

a. True.b. False.

173. PMO means Project Management Office:

a. True.b. False.

174. Engaging information, information systems and the IT organization in partnership with the business to continuously improve and innovate business process and management systems are aspect of:

a. Outward facing Lean IT.b. Inward facing Lean IT.

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175. The 3 M’s:

1. Muda = unevenness.2. Mura = unevenness.3. Muri = overburden.

a. 1 is wrong.b. All are wrong.c. All are correct.d. 2 is wrong.

176. ROI = Return On Investment:

a. True.b. False.

177. S&OP = Sales and Operations Planning:

a. True.b. False.

178. SOA = Service Oriented Architecture:

a. False.b. True.

179. TQM = Total Quality Maintenance:

a. False.b. True.

180. What is NOT an aspect of inward-facing Lean IT:

a. Helping the IT organization achieve operational excellence.b. Engaging information.c. Applying the principles and tools of continuous improvement to IT operations, services, software development and projects.

181. Kaizen events:

1. Are focused short-term improvement efforts.2. Usually involve a cross functional team.3. Last from three to five days.4. Preparation can take place over several months.

a. All are correct.b. None of the above is correct.c. 4 is wrong.d. 1, 2 and 3 are wrong.

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182. Which is/are NOT Kanban boards used in Lean software development:

1. Backlog.2. In process.3. To Do.4. Burndown.

a. 3.b. 4.c. 1 and 2.d. 3 and 4.

183. Which is NOT a level of the Lean Enterprise Principles Pyramid:

1. Capstone.2. Flow.3. Systems Thinking.4. Behavior.

a. None of the above is a level.b. All of the above are levels.c. 3.d. Capstone.

184. Which of the following is/are NOT a concern of the business:

1. Endless “firefighting”.2. Conflicting priorities.3. Resource thrashing.4. Poor data quality.

a. All of the above.b. None of the above.c. 1 and 3.d. 2 and 4.

185. Business perceptions of IT and the IT organization include the following concerns EXCEPT:

1. Complexity.2. Regulatory requirements.3. Misdirection.4. Information overload.

a. All of the above.b. None of the above.c. 2.d. 4.

186. Common IT concerns and challenges include:

1. Scheduling of shared resources and services.2. Regulatory requirements.3. Outsourcing.4. Budget constraints.

a. All of the above.b. None of the above.c. 2.d. 4.

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187. The timeline of continuous improvement is divided into:

1. Age of scientific management.2. Age of engagement.3. Age of integration.

a. True.b. False.

188. The lean enterprise principles pyramid:

1. Has 5 levels.2. The foundation level has 3 elements.3. The perspective level has 3 elements.4. The other levels have 2 elements.

a. All of the above are correct.b. 1, 2 and 3 are correct.c. 2, 3 and 4 are correct.d. None of the above is correct.

189. Strategy deployment:

1. Is a management system to align daily work with strategy.2. Is also known as policy deployment.3. Is also known as hoshin kanri.4. Is also known as hoshin planning.

a. All of the above are correct.b. 1, 2 and 3 are correct.c. 2, 3 and 4 are correct.d. None of the above is correct.

190. The foundation level of the lean enterprise principles pyramid:

1. Has 3 elements.2. Constancy of purpose is an element.3. Respect for people is an element.4. Pursuit of perfection is an element.

a. All of the above are correct.b. 1 is correct.c. 2, 3 and 4 are correct.d. None of the above is correct.

191. The time management matrix has 2 axes: Urgent/Not Urgent and Important/Not Important.

a. False.b. True.

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192. The perspective level of lean enterprise principles pyramid:

1. Has 4 elements.2. Voice of the customer is an element.3. Quality at the source is an element.4. Pursuit of perfection is an element.5. Systems thinking is an element.

a. All of the above are correct.b. 1 is correct.c. 2, 3 and 5 are correct.d. None of the above is correct.

193. Unnecessary complexity:

1. Arises from inappropriate design of business processes and supporting information systems.2. Is called the waste of over processing by lean practioners.3. Is excessive work where cost and complexity exceed the benefits.

a. All of the above are correct.b. 1 is correct.c. 2 and 3 are correct.d. None of the above is correct.

194. Enterprise alignment develops in dimensions:

1. Vertically: aligning strategy up and down the hierarchal organization.2. Horizontally: aligning every stakeholder across every functional silo, process and project.3. Vertically and horizontally: aligning information systems, both manual and computerized.

a. None of the above is correct.b. 3 is correct.c. 1 and 2 are correct.d. All of the above are correct.

195. The appropriate balance between efficiency and flexibility is known as agility.

a. False.b. True.

196. The age of scientific management:

1. Begins in 1890 and stops in 1940.2. Is pioneered by Taylor, Gilbreth and Ford.3. Introduced standardized manufacturing methods, simplified work and division of labor.4. Involved the ideas of Deming, Juran and Feigenbaum.

a. None of the above is correct.b. 4 is correct.c. 1, 2 and 3 are correct.d. All of the above are correct.

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197. In the importance paradigm:

1. Urgent and important result in reactive.2. Urgent and not important result in deceptive.3. Not urgent and important result in proactive.4. Not urgent and not important result in NVA work.

a. None of the above is correct.b. 4 is correct.c. 1, 2 and 3 are correct.d. All of the above are correct.

198. The evolution of a lean culture:

1. Begins with the adoption of continuous improvement tools.2. Is followed by the formation of behavior-driven systems.3. Is guided by shared values and principles.

a. All 3 are correct.b. 1 and 3 are correct.c. All 3 are NOT correct.d. 2 is correct.

199. Efficiency and flexibility in agility have the following elements:

1. Efficiency: stable processes, standard procedures, predictable outcomes, minimal disruption and rigidity.2. Flexibility: fluid processes, responsive procedures, less predictable outcomes, frequent changes and adaptability.

a. Both are correct.b. Both are wrong.c. 1 is correct.d. 2 is correct.

200. The essence of Deming’s work is contained in 14 principles. Among them are:

1. Create a constancy of purpose.2. Cease dependence on mass inspection.3. Institute training on the job.4. Eliminate exhortations (slogans).5. Develop top management commitment and action.

a. All 5 are correct.b. All 5 are wrong.c. 1, 3 and 5 are correct.d. 2 and 4 are correct.

201. Six sigma and lean share many similarities:

1. Both seek to establish ongoing continuous improvement.2. Both focus on delivering customer-defined value.3. Both pursue the reduction of non-value-added work.4. Both apply a disciplined closed-loop improvement methodology.

a. All 4 are correct.b. All 4 are wrong.c. 1, 3 and 4 are correct.d. 2 and 4 are correct.

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202. Six Sigma applies DMAIC as improvement methodology, Lean applies PDCA.

a. True.b. False.

203. The age of engagement runs from 1940 till 1995.

a. True.b. False.

204. The Quality Movement:

1. Shifted the primary focus of process improvement from productive efficiency to delivering value to the customer.2. Has some famous names attached to it: Deming, Juran and Feigenbaum.

a. Both are wrong.b. 1 is correct.c. 2 is correct.d. Both are correct.

205. The TOC (Theory of Constraints):

1. Is introduced by Eli Goldratt.2. Is published in “The Goal”.

a. Both are correct.b. Both are wrong.c. 1 is correct.d. 2 is correct.

206. Womack and Jones introduced a five-step process for lean improvement. Which one is/are NOT one or more of the five steps:

1. Specify value from the perspective of the end customer.2. Identify all steps in the value stream, eliminating those activities, processes, and policies that do not create value.3. Establish a constancy of purpose.4. Let the customer demand pull value from the next upstream activity.5. Pursue perfection through continuous improvement.

a. 2 and 4.b. 1, 3 and 5.c. 3.d. 5.

207. The stages of lean transformation do NOT have one or more of the next stages:

1. Establish a sense of urgency.2. Build a strategy.3. Form a powerful guiding coalition.4. Create a vision.5. Communicate the vision.6. Empower others to act on the vision.7. Plan for and create short-term wins.8. Consolidate improvements and produce more change.9. Institutionalize new approaches.

a. 2 and 8.b. 2.c. 5 and 8.d. 6.

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208. With respect to balancing people, process and technology:

1. Balancing process and people without technology leads to frustration and inefficiency and high costs of operation.2. Balancing people and technology without process leads to automated chaos and confusion and poor customer service.3. Balancing process and technology without people leads to alienation and turnover and under-utilized systems.

a. All are wrong.b. All are correct.c. 1 and 3 are wrong.d. 2 is wrong.

209. The “initiate”” phase in traditional project management is equal to:

1. The plan phase in Lean PDCA.2. The define phase in Six Sigma DMAIC.3.The A3/ VOC/Gemba in Lean/Six Sigma tools.


210. In conventional project management the focus is on tactical execution where as in lean project management the focus is on stra-tegic alignment/voice of the customer.

a. True.b. False.

211. The five phase of project management are: initiate, plan, execute, monitor and control and close:

a. True.b. False.

212. Aspects of inward facing lean IT are:

1. Lean IT operations: ITIL and cloud computing.2. Lean software development.3. Applying lean to project management.


213. The age of integration:

1. Starts is 1996.2. Starts with “Lean Thinking” by Womack and Jones.

a. Both are correct.b. 1 is correct.c. 2 is correct.d. Both are wrong.

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214. Constancy of purpose:

1. Leadership provides the direction and clarity we need to focus on the things that matter most, maintaining clarity on important long-term objectives.2. Is at the foundation level of the lean enterprise principles pyramid.3. Is called by Deming.4. Focuses thinking and behavior, aligning effort and getting everyone rowing in the same direction.


215. What aspects of Respect for people are correct:

1. Drives employee development, encourages participation, and improves supplier, customer and community relations.2. When people sense that their input is disregarded or not respected, they tend to withdraw their support, concern and active participation.3. Unlocks personal excellence and creative potential.


216. The improvement methodology used in Six Sigma and Lean are:

1. DMAIC in Lean.2. DMAIC in Six Sigma.3. PDCA in Lean.4. PDCA in Six Sigma.

a. All are correct.b. 2 and 3 are correct.c. 1 and 4 are correct.d. None of the above is correct.

217. SMART targets are developed in which stage:

a. Plan.b. Do.c. Check.d. Act.

218. Six Sigma emphasizes quality through controlling process variation (mura). Lean’s focus is flow attained from eliminating non-value-added activities (muda).

a. True.b. False.

219. Lean improvements activity (kaizen) ranges from a few hours to a few months. Six Sigma projects last 3 to 12 months.

a. True.b. False.

220. Large scale lean improvements representing radical or even revolutionary changes are called kaikaku.

a. True.b. False.

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221. A strict zero-defects mentality too early adopted in the life cycle discourages creativity, continuous learning and experimenta-tion:

a. True.b. False.

222. Humility:

1. Humility is a very effective catalyst for a culture of continuous improvement.2. Humility is embodied in the Japanese term hansei.

a. 1 is correct.b. 2 is correct.c. Both are wrong.d. Both are correct.

223. 5 Whys:

1. Is a method for pushing people to think about root causes.2. Prevents a team from being satisfied with superficial solutions that won’t fix the problem in the long run.

a. Both are correct.b. None are correct.c. 1 is correct.d. 2 is correct.

224. 5S:

1. Set in order = Simplify.2. Shine = Sweep.3. Sustain = Self-Discipline.

a. All are correct.b. 1 and 3 are correct.c. 2 is correct.d. None are correct.

225. The deliverables of the analyze stage in DMAIC are:

1. Documentation of potential causes considered in your analysis.2. Data charts and other analyses that show the link between the targeted input and process (Xs) variables and critical output (Y).3. Identification of value-added and non-value-added work.4. Calculation of process cycle efficiency.

a. 1 and 3 are correct.b. 2 and 3 are correct.c. 3 and 4 are correct.d. All are correct.

226. Benchmarking:

1. Benchmarks are measures that have already been achieved by some company, somewhere.2. They tell you what’s possible so you can set goals for your own operations.3. Benchmarking can be very helpful to inject new ideas into the process and borrow the good ideas from other companies/industries.

a. All are correct.b. 1 and 3 are correct.c. 2 and 3 are correct.d. None are correct.

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227. Brainstorming:

1. Produces many ideas or solutions in a short time.2. Stimulates the creative thinking process.3. Helps make sure that all group members’ ideas are considered.


228. The purpose of a C&E matrix is to identify the few key process input variables that must be addressed to improve the key pro-cess output variables(s):

a. False.b. True.

229. A cause & effect diagram = a fishbone diagram = a Ishikawa diagram:

a. False.b. True.

230. The pursuit of perfection:

1. Is a building block in the foundation.2. Is not a program or project.3. Is a component of daily work.


231. The Time Management Matrix is introduced by Dr Stephen Covey in The 7 Habits of Highly Effective People:

a. False.b. True.

232. Fire Fighting, Crisis Management, Interruptions and rework belong in which quadrant:

a. Important, Urgent.b. Important, Not Urgent.c. Not Important, Urgent.d. Not Important, Not Urgent.

233. The reactive quadrant is:


234. The proactive quadrant is:


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235. Lean thinking, Alignment, Prioritization, Planning, Prevention, Preparation and Measurement belong in which quadrant:


236. The deceptive quadrant is:


237. NVA is Non-value-added work:

a. False.b. True.

238. Which aspect does NOT belong to the three C’s:

a. Clear.b. Consistent.c. Complete.d. Correct.

239. The takt rate is the amount of product or service required by customers over a continuous period of time.

a. False.b. True.

240. For implementing DMAIC there are 2 primary options:

1. Project-team approach.2. Kaizen approach.

a. 1 is correct, 2 not.b. 2 is correct, 1 not.c. Both are correct.d. The correct options are missing.

241. The third level of the pyramid contains:

1. Voice of the customer.2. Quality at the source.3. Systems thinking.4. Pursuit of perfection.

a. 4 is correct.b. 1, 2 and 3 are correct.c. None of the above is correct.d. 3 and 4 are correct.

242. The techniques like interviews and surveys that are used in the VOC are used to develop critical-to quality requirements:

a. False.b. True.

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243. Quality at the source means:

1. Doing it right, the first time, every time.2. The “we’ll fix it later” approach is NOT accepted.3. More time is available to do the work customers are paying for.

a. 3 is correct.b. All are correct.c. None of the above is correct.d. 1 and 2 are correct.

244. Systems thinking:

1. Is the ability to view the interconnected processes that make up the entire value stream.2. Avoids solutions that create localized optimization and silo behavior.3.Stimulates the creative potential of employees by broadening their horizons.

a. 3 is correct.b. All are correct.c. None of the above is correct.d. 1 and 2 are correct.

245. Which of these need not be a feature of Lean metrics?

a. They are fundamental for decision-making purposes. b. Building a Lean enterprise is an important basis for good metrics. c. They should be made keeping in mind the goals of the competitor. d. They should be simple to understand and presented in a clear manner. 246. The various kinds of Kanban include:

a. Supplier Kanban. b. In-Factory Kanban. c. Customer Kanban. d. In-House Kanban. e. All of the above. 247. What is the function of SMED?

a. To increase output and quality losses. b. To reduce the changeover in a process. c. To improve supplier relations. d. All of the above. 248. Which of the following is not a Lean Tool?

a. Standardization. b. 5s-Cando. c. Kanban. d. Design of Experiments. 249. What is the main function of Lean?

a. Eliminating muda. b. Increasing cycle time. c. Downsizing personnel.d. Improving process capability.

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250. The Kano model is:

a. A prototype of plastic printing technology.b. A Japanese flowcharting technique.c. A model of customer satisfaction and product development.d. A theory of organizational change and human resource deployment.

251. On the fourth level of the pyramid are:

1. Flow.2. Pull.3. JIT.

a. 1 and 3.b. 2 and 3.c. None of the above.d. 1, 2 and 3.

252. Which is NOT a result of flow:

a. Better quality.b. Higher stocks.c. Shorter response time.d. Better customer service.

253. The evolution of a lean culture often begins with the adoption of continuous improvement tools, followed by the formation of behavior-driven systems, guided by shared values and principles.

a. False.b. True.

254. Which stage (A, B or C) is NOT correctly associated with D, E or F:

a. Principles d. Embedding Principles into Cultureb. Systems E. Structuring Tools into a Systems Context

c. Tools F. Creating Point Solutions

a. All are correct.b. A.c. B.d. C.

255. The principal focus of lean is problem solving for the primary purpose of delivering value to the customer, achieved by the syste-matic elimination of waste throughout the value stream.

a. False.b. True.

256. Which of the following percentage of time is spent on value adding activities in a typical process?

a. 0,05b. 0,35c. 0,6 d. 1

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257. In a software development process, the activity of testing would in most cases be considered as:

a. A value-adding and necessary activity.b. A value-adding but unnecessary activity.c. A non-value-adding but necessary activity.d. A non-value-adding and unnecessary activity.

258. Which of the following types of waste are classified as waste types in the original Lean terminology? (The IT equivalent of each original waste type is listed in brackets.):

1. Overproduction (exceeding expectations or service levels, over-engineering software, and over documentation).2. Waiting time (tickets and/or software awaiting activity i.e. testing, approval, decisions). 3. Movement (user-interfaces which force the user to enter the same data several times or perform excessive mouse-clicks).4. Bad processes (analysis made too late in the process, bottlenecks and excessive activities in a process). 5. Bad communication from management (unclear signals, decisions or coordination by management). 6. Stock (hardware and software in stock, requirement specifications and releases). 7. Transport (moving hardware and physical case files around). 8. Errors and misunderstandings (not fully understanding the actual needs of customers, bugs in a piece of software or missing information on a ticket).

a. 1, 2, 3, 4, 5, 6 and 7. b. 1, 2, 3, 4, 6, 7 and 8. c. 1, 2, 3, 5, 6, 7 and 8. d. 2, 3, 4, 5, 6, 7 and 8. 259. Which technique would NOT be considered a Lean Waste Analysis method?

a. Frontloading.b. 5 Why’s. c. Ohno’s Circle. d. Kaizen.

260. Which of the following changes to a support process would generate the LEAST result in terms of better flow? a. Ensure that several employees are able to perform critical/all tasks (remove bottlenecks). b. Give more user rights to employees, to allow them to perform the complete transaction and not have to hand over the ticket (reduce the amount of activities). c. Remove activities that do not add value (fewer handovers).d. Ensure that every ticket is checked before passing further in the process (increased control).

261. Reducing variance in for instance a server configuration process will most likely result in a better flow in the work because of:

1. Higher predictability. 2. Better opportunities for the HR department to create career paths. 3. More employees will be able to understand the technical details of the process.4. Better ability to man the different activities to match the actual need.

a. 1.b. 1 and 3. c. 1 and 4. d. None.

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262. Which of the following statements describes frontloading? 1. Better match between the it-systems used in the process, and the competences needed to use them.2. Fewer errors and misunderstandings, due to more information and knowledge early in the process.3. Critical issues are moved to the top of the agenda on all status meetings. 4. More involvement of customers in the beginning of the process to ensure less waste. a. 1 and 3. b. 2, 3 and 4. c. 2 and 4. d. All of them.

263. Takt in a software development project could be:

1. An alignment of meetings at all levels to allow the shortest amount of waiting time for decisions. 2. A fixed agreement on when status meetings are held in the project. 3. An agreed process for submitting timesheets and expenses. 4. A template for how stakeholder management must be documented.

a. 1 and 2. b. 1 and 3. c. 2, 3 and 4.d. All of them.

264. An alternative system for initiating activity in a process is called the pull-system, as used in Toyota. Which of the following state-ments BEST describes the triggering of an activity in Toyota:

a. A Kanban card is sent to a workstation upstream to the station needing an item, thus triggering the production of the needed item in the de-sired quantity. b. An employee walks between the different workstations overseeing the process and spotting the need for items in the different worksta-tions. c. The need for an item is entered into a computer system, which calculates a production plan and sends out messages to the different stations on what to produce, and when. d. A workstation may trigger a song to play when an item is needed, thus informing the manager, that he/she needs an item.

265. Pull systems have been implemented in software development processes in several places. Which are some of the reasons for im-plementing a pull system in a software development process? 1) To have better visibility with what is pulled into any given release.2) To be better able to control the amount of code under development (work-in progress). Thus controlling the cost and complexity in the process. 3) To ensure visibility for everybody on what is being developed, in what quantities and for which customer. 4) To ensure that nothing is developed, without there being an actual demand for it. a. 3 and 4. b. 2 and 4. c. 1 and 2. d. All of them.

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266. In Lean software development, the pull-system can be implemented in the form of a Kanban-system. When implementing such a Kanban-system, which are the key focus areas? 1) Measure and improve the cycle time (or lead-time).2) Set goals for quality and improve it. 3) Limit work-in-progress. 4) Ensuring that most of the employees are trained in the strategy of the department. a. 1, 2 and 3. b. 1, 2 and 4.c. 2, 3 and 4. d. All of them.

267. Which of the following descriptions BEST match the reason for using control charts in an organization? a. With control charts management is better able to monitor and control employees. b. Control charts are created and maintained for each asset in the company to keep track of master data, maintenance information etc.c. Control charts are used in departments to keep track of who brings cake to the department meeting.d. A control chart is used to view on a graph the level of a particular indicator over time, to be able to identify statistical outliers, trends and deciding factors.

268. Many companies that have implemented Kaizen, have implemented it using Kaizen boards and Kaizen meetings. How often are these regular Kaizen meetings usually held to focus efforts on small improvements? a. Every hour. b. Every week. c. Every 6 months. d. Every year.

269. The Kaizen board-meeting manager has responsibilities towards conducting the meetings in the best way possible. Which of the following statements is NOT part of that responsibility?

a. Ensure that all participants at the meeting are heard. b. Take primary responsibility for the implementation of most of the ideas. c. Encourage more ideas for the board. d. Keep track of the time.

270. When progressing from a Lean project to a Lean organization; there are several pitfalls to be avoided, in order to have a better chance of success in the long term. Which of the following are important factors to succeeding in the long term with Lean?

1. Making Lean part of the culture in the company. 2. That benefits are actually achieved. 3. Focus on continuous improvements.4. Management understanding and support.

a. 2 and 3. b. 1, 2 and 3. c. 3 and 4. d. All of them.

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271. Which of the following situations would be considered waste in an operations process?

1. Pcs in the stock. 2. Preventive maintenance on a server. 3. The technician enquiring for address information from the customer. 4. Completing and storing backups.

a. None. b. 1, 2 and 3. c. 1 and 3. d. All of them.

272. Which of the following is NOT among the five Lean principles? a. Pull. b. Perfection. c. Optimization. d. Flow. 273. Which of the following is the CORRECT definition of a Value Stream?

a. A sum-up of the entire value stock of any company. b. All the activities required to bring a specific product through the critical management tasks of any business. c. The process by which a service adds value to its target customers. d. A standard flow of products in a company covering both initial manufacturing and final shipment to the customer.

274. What would be the next step in the standardized work process?

1st Establish. 2nd Communicate. 3th Follow. 4th ?

a. Strengthen. b. Inform. c. Act. d. Improve.

275. Which of the following plays an important part in making value flow?

a. Muri. b. Poka-yoke. c. Kanban. d. Jidoka.

276. A3 Thinking:

1. Is based on the scientific method.2. Uses PDCA.3. Is at the heart of lean.

a. 1, 2 and 3 are correct.b. None of the above is correct.c. 2 is correct.d. 3 is correct.

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277. Value stream mapping visually depicts the flow of information, materials, and work across functional silos with an emphasis on quantifying wastes, including time and quality.

a. False.b. True.

278. Process Kaizen does NOT:

a. Focus on people.b. Focus on processes.c. Focus on elimination of waste.d. Focus on elimination of overburden.

279. Kaizen project can last from several weeks to up to three months:

a. False.b. True.

280. Daily Kaizen = Daily improvement = Kaizen blitz:

a. True.b. False.c. Option is missing: Daily stand-up.d. There are no daily kaizen’s, improvements or blitz.

281. Gemba is Japanese for:

a. Real or actual place.b. Waste.c. Variation.d. Overburden.

282. 5S:

1. Is a workplace organization method.2. Is: Sort, Set in order, Shine, Standardize and Sustain.3. Lays the groundwork for the visual workplace.4. Eliminates visual and mental noise.

a. 1 and 4 are correct.b. None of the above is correct.c. 2 and 3 are correct.d. All are correct.

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283. What item should be in 1, 2, 3 and 4 in the table of the contrasting attributes of lean IT and traditional IT:

Lean Traditional IT

Change management Organic, incremental and continuous

Engineered and planned large events

Organization 1 Central command and control

Measures

Top-down and bottom-up performance measures linking improvement initiatives to strategic

goals

3

Knowledge management Generalization SpecializationEducation 2 Task focus

Definition of success Speed and agility 4

a. 1 = Cross-functional teams, 2 = Process focus, 3 = Cost containment and uptime, 4 = Stability.b. 1 = Process focus, 2 = Cost containment and uptime, 3 = Stability, 4 = Cross-functional teams.c. 1 = Cost containment and uptime, 2 = Stability, 3 = Cross-functional teams, 4 = Process focus.d. 1 = Stability, 2 = Cross-functional teams, 3 = Process focus, 4 = Cost containment and uptime.

284. Manufacturing: Excess raw material, work in process, and finished goods. Office: Work accumulating in physical and virtual inboxes, excess physical files. IT: Excessive information causing searching and version control problems, excessive backlog and work in progress.

These are examples of which kind of waste:

a. Overproduction.b. Delays.c. Inventory.d. Motion.

285. SCOR = Supply Chain Operations reference Model:

a. False.b. True.

286. The most considered environmental waste caused by IT operations are:

1. Data center efficiency.2. End user computing energy efficiency.3. Toner and paper consumption.4. Ethical handling of electronic waste.


287. The triple bottom line consists of: People, Planet and Profit:

a. False.b. True.

288. In workplace organization the 5S’s are: Sort, Straighten, Shine, Standardize and Sustain:

a. False.b. True.

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289. The purpose of the Improve stage in DMAIC is to learn from pilots of the selected solution(s) and to execute full-scale implemen-tation:

a. False.b. True.

290. An andon board:

1. Can be done with a simple whiteboard.2. Can also involve electronic displays.3. Is a status indicator.4. Alerts team members to emerging problems.


291. Activity based costing is a management accounting system that assigns costs to products based on the amount of resources used in order to design, order or make a product:

a. False.b. True.

292. Batch and queue is the mass production practice of making large lots of a part and than sending the batch to wait in the queue before the next operation in the production. Contrast with single-piece flow:

a. False.b. True.

293. A Brownfield:

1. A brownfield is an established design or production facility operating with mass-production methods and systems of social organization.2. Is in contrast with single-piece flow.


294. Cells is/are:

1. The layout of machines of different types performing different operations in a tight sequence.2. Typically in a U-shape.3. Permit single-piece flow and flexible deployment by means of multi-machine working.4. In contrast with process villages.

a. 1 and 3 are correct.b. 2 and 4 are correct.c. All are correct.d. All are wrong.

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295. The power of Lean IT includes knowing when NOT to use technology because:

1. The vast majority of problems are caused by faulty processes.2. The vast majority of problems are caused by people.3. The vast majority of problems are caused by technology.

a. None of the above is correct.b. All of the above are correct.c. 1 is correct.d. 2 and 3 are correct.

296. Chaku-chaku means load-load:

a. True.b. False.

297. The Shingo Prize for Operational Excellence endorses a transformational model that characterizes the enterprise as five busi-ness systems:

1. Customer relations.2. Product & service development.3. Cloud computing.4. Operations.5. Infrastructure.6. Supply.7. Quality support.8. Management.

a. 1, 2, 3, 4 and 5 are correct.b. 1, 2, 4, 6 and 8 are correct.c. 4, 5, 6, 7 and 8 are correct.d. 3, 5, 6, 7 and 8 are correct.

298. The term “changeover” applies whenever a production device is assigned to perform a different operation.

a. False.b. True.

299. The three C’s are:

1. Cloud.2. Clear.3. Continuous.4. Complete.5. Constancy.6. Correct.

a. 1, 3 and 5 are correct.b. 2, 3 and 5 are correct.c. 2, 4 and 5 are correct.d. 2, 4 and 6 are correct.

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300. Cycle time:

1. Is the time required to complete one cycle of an operation.2. If the cycle time for every operation in a complete process can be reduced to equal takt time, products can be made in single-piece flow.

a. 1 is correct.b. 2 is correct.c. None of the above is correct.d. Both are correct.

301. Matrix management is management that creates a horizontal flow of authority by drawing people from different functional disci-plines to support department-spanning processes without removing them from their respective positions.

a. True.b. False.

302. The DMAIC approach to problem solving stands for Define, __________, Analyze, Improve and Control.

a. Manage.b. Measure.c. Memorize.d. Manipulate.

303. Voice of the Customer is a Lean Six Sigma technique to determine the ___________ attributes of a product or service.

a. Desirable.b. Beneficial.c. Critical-to-Quality.d. Preferred.

304. When we assess the Voice of the Customer we are attempting to determine the gaps in our processes between “what is” and __________________.

a. “What isn’t”.b. “What will make money”.c. “What will cost less”.d. “What should be”.

305. What does DMAIC stand for?a. Define Measure Analyse Improve Continue. b. Define Measure Assess Improve Control. c. Define Measure Analyse Implement Control. d. Define Measure Analyse Improve Control.

306. What is an Ishikawa diagram NOT used for?a. Identify potential root causes of a failure mode. b. Provide a visual display of the X inputs that are driving the Y output. c. Reject the null hypothesis in a hypothesis test. d. Allow a systematic and balanced assessment of key drivers in a process.

307. What is the Kano Model?a. A prototype Japanese electric car. b. An analytical framework for measuring random variation in a process. c. A model for understanding the key drivers of customer satisfaction. d. A formula for quantifying the yield of online advertising platforms.

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308. The advantages of training executives and managers in Lean Six Sigma concepts before other production personnel include:

a. Managers have more free time for training.b. Managers must lead the deployment of Six Sigma.c. Managers must understand the concepts if their full support is expected.d. Manager will validate the overall impact of the training.

a. BC.b. BCD.c. ABCD.d. ABC.

309. Lean Six Sigma executives who provide financial support to projects are referred to as:

a. Process owners.b. Champions.c. Master Black Belts.d. Trained facilitators.

a. AD.b. ACD.c. BC.d. AB.

310. A work schematic that details the relationship between inputs, processes, outputs, customers and feedback is called a:

a. A subsystem.b. A SIPOC diagram.c. A system diagram.d. An activity network diagram.

311. Juran often describes a parallel between HIS quality sequence and which of the following management processes?

a. Production.b. Financial.c. Design engineering.d. Auditing.

312. On a process flow diagram, the component that indicates a need for correction is called:

a. Inputs.b. SIPOC.c. Feedback.d. Outputs.

313. Identify a tool that is typically used in the Define/ Measure phase of Six Sigma DMAIC, and is useful in developing high-level process maps:

a. FMEA. b. Cause and Effects Diagram.c. Hypothesis Test. d. SIPOC.

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314. In establishing the base line performance of a process it is important to:

a. Use statistical techniques to determine significant effects. b. Involve the accounting and finance department when financial metrics are developed. c. Only use the most recent data.d. Use bar charts to display significant differences graphically.

315. Which question is part of a Stakeholders Analysis?

a. What concerns can you anticipate for each Stakeholder? b. What positive outcomes exist for each Stakeholder? c. What will be your message for each Stakeholder? d. All of the above.

316. Overproduction, scrap, waiting, and excess motion are all forms of:

a. Ishikawa. b. Muda. c. Muri. d. Poka Yoke.

317. The sequence a team actually follows through the phases of DMAIC:

a. Is always DMAIC. b. Is always DMAIC but may involve looping back to previous steps. c. Is determined solely by the Green or Black Belt. d. Should be DIC if possible to save time and money.

318. Customers are willing to pay for it, it changes the product or service, and it is done right the first time. This describes:

a. CTQ requirements. b. The PDCA cycle. c. TIM WOOD. d. None of the above.

319. Which types of waste will NOT occur in an office environment?

I Inventory II Waiting III Motion IV Defects

a. I and II.b. I, II and III.c. II, III and IV.d. All types may occur. 320. An organized and disciplined approach to problem solving in most six sigma organizations is called:

a. SIPOC.b. DMAIC.c. PDCA.d. DPMO.

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321. From an upper management perspective, what has been the principal motivating factor in embracing six sigma?

a. Bottom line results.b. Market share growth.c. Defect reductions.d. Customer focus.

322. Kanban is closely associated with:

a. Elimination of non-value added activities in the process.b. The development of future state process stream map.c. Making problems visible is a process.d. The control of material flow.

323. SIPOC process map is a tool best used for:

a. Identifying requirements between customers and suppliers.b. Drilling down the Y=f(x).c. Determining what is currently being provided.d. Assists in determining a project’s timeline.

324. The Japanese word for waste is:

a. Hudat.b. Muda.c. Nioibukuro.d. Keikaku.

325. A small distribution warehouse moves a single crate of product six times before it is loaded for shipment. This is an example of which element of waste:

a. Defects.b. Inventory.c. Motion.d. Conveyance.

326. 5S can best be described as a toolkit to ________ a process in the control phase.

a. Remove labor for.b. Overly lengthen the six sigma project for.c. Confuse.d. Stabilize.

327. The most basic of all lean tools that support the other lean tools is best known as:

a. Kanban.b. Kaizen.c. Kaikaku.d. 5S.

328. The foundation of a visual factory is:

a. Technically skilled workers.b. Work space with active 5S.c. Inventory control.d. Breakthrough projects.

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329. The goal of the control phase is to:

a. Define the project’s purpose and scope.b. Focus your improvement effort by gathering information about the current situation.c. Maintain the gains you have made by standardizing your work methods and sustaining the lessons you have learned.d. Develop, test and implement solutions that address root causes.

330. The goal of the improvement step is to:

a. Define the projects purpose and scope.b. Focus your improvement effort by gathering information about the current situation.c. Identify root causes and confirm them with data.d. Develop, test and implement solutions that address root causes.

331. 5S stands for ______.

a. Sort, straighten, shine, subsidize, sustain.b. Sort, stratified, shine, standardize, socialize.c. Support, stratified/storage, shine, standardize, sustain.d. Sort, Straighten/storage, shine, standardize, sustain.

332. Poka yoke is a lean tool used for ____.

a. Cost estimation.b. Counting errors.c. Preventing errors.d. None of the above.

333. The goal of the analyze phase is to:

a. Define the project’s purpose and scope.b. Focus your improvement effort by gathering information about the current situation.c. Identify root causes and confirm them with data.d. Develop, test and implement solutions that address root causes.

334. Value added analysis helps to determine the share of activities that ____to the product/service.

a. Ads values.b. Don’t add value.c. Add cost.d. Reduce cost.

335. The term Sigma is a measurement of:

a. Profit of a company.b. Amount of variation present in a process relative to customer requirements and specifications.c. Innovation rate based on incremental and radical improvements.d. Market share increase.

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336. In value stream analysis, the following symbol shows:

a. Go see.b. Search.c. Operator.d. Electronic inspection.

337. The goal of the measure step is to:

a. Define the project’s purpose and scope.b. Focus your improvement effort by gathering information about the current situation.c. Identify root causes and confirm them with data.d. Develop, test and implement solutions that address root causes.

338. In 5S sorting means _____.

a. Redesign the layout to gain shorter ways.b. A clean work environment is an indicator of quality.c. Remove unnecessary items.d. Decide who is responsible for each task.

339. Poka yoke is a Japanese word for ___.

a. Error tolerant.b. Cost reduction.c. Increase profit.d. None of the above.

340. Value added activities meet all the following criteria except:

a. The product is physically changed (criterion to be amended for service processes).b. The customer is willing to pay for it.c. Rectifying poor quality or apologizing to dissatisfied customers.d. It is done right the first time.

341. DMAIC stands for:

a. Define, Measure, Analyze, Imagine, Control.b. Dedicated, Measure, Analyze, Improve, Control.c. Define, Measure, Analyze, Improve, Control.d. Define, Measure, Analyze, Improve, Choose.

342. The Japanese word for waste is:

a. Niokiour.b. Bistet.c. Janda.d. Muda.

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343. Customer satisfaction is:

a. Achieved through higher quality.b. Less important than price of product/service.c. Achieved through always offering the lowest price and quality.d. None of the above.

344. In process analysis, the following symbol is used for:

a. Start point.b. End point.c. Establishing the borders of the process.d. All of the above.


a. Production Kanban.b. Batched Kanban.c. Withdrawal Kanban.d. Signal Kanban.

346. In 5S straighten/storage means ___:


347. Poka yoke system consists of following mechanism, except ____.

a. Detection mechanism.b. Trigger mechanism.c. Reverse mechanism.d. Reaction mechanism.

348. Which of the following activities are non-value added:

a. Administration.b. Waiting time.c. Defect inspection.d. All of the above.

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349. A firm’s warehouse moves a single crate of product 8 times before it is loaded for shipment; this is an example of ____waste.

a. Organizational.b. Inventory.c. Transportation.d. Motion.

350. In process analysis, the following symbol is used to show:

a. Decision.b. Input or output.c. Activity.d. Connection of processes.

351. In 5S shining means ___.


352. Which of the following are types of waste?

a. Transport –moving people, products & information.b. Waiting.c. Over processing.d. All of the above.

353. Which of the following is/are quality characteristics of goods or services:

a. Reliability.b. Performance.c. Maintainability.d. All of the above.

354. In process analysis, the following symbol is used to:

a. Demonstrates the decision points and shows where infinite loops appear in the process.b. Illustrate a process path/flow.c. Illustrate the activities in their order of execution.d. Establishes the borders of the process.

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355. In 5S standardizing means ____.


356. SIPOC stands for:

a. Supplier Input Program Output Customer.b. Supplier Input Process Output Consume.c. Supplier Input Process Operate Customer.d. Supplier Input Process Output Customer.

357. In 5S sustaining means ____.

a. Redesign the layout to gain shorter ways.b. Involve all the employees, develop 5S awareness.c. Remove unnecessary items.d. Decide who is responsible for each task.

358. Which of the following are types of waste?

a. Over production.b. Inventory.c. Unexploited knowledge.d. All of the above.


a. Environmental impact.b. Appearance.c. Flawlessness.d. All of the above.


a. Connection of processes.b. Illustrates a process path/flow.c. Establishes the borders of the process.d. Boundaries.

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361. Which of the following is a type of waste:

1. Waiting for employees as unfinished work is completed.2. Unnecessary process steps.3. Over production.4. …

a. Only 1.b. Only 2 & 3.c. Only 3 & 4.d. All of the above.


a. Safety.b. Durability.c. Credibility.d. All of the above.


a. Establishes the borders of the process.b. Connection of processes.c. Electronic input or output.d. Illustrate the activities in their order of execution.


a. Communication.b. Responsiveness.c. Empathy.d. All of the above.

365. The goal of the define step is to:

a. Identify root causes and confirm them with data.b. Focus your improvement effort by gathering information about the current situation.c. Define the project’s purpose and scope.d. Develop, test and implement solutions that address root causes.

366. SIPOC helps to:

a. Identify the relevant process steps in the project.b. Structure complex projects.c. Achieve clarity regarding the project focus.d. Both A and C.

367. A value stream map helps to:

a. Identify cost factors of the process.b. Visualize the process flow.c. Identify most important defects in the product.d. None of the above.

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368. A value stream map includes all ____ that are necessary to deliver a product or service to the customer.

a. Requirements.b. Demands.c. Activities.d. None of the above.


a. External locations.b. Finished service to customer.c. Transaction process.d. Inventory.

370. Which of the following activities is not shown in value stream map?

a. Value added.b. Non value added.c. Business non-value added.d. Marginal cost added.


a. External locations.b. Inventory.c. Illustrates a finished service to customer.d. Transactional/dedicated process.

372. SIPOC is a _____ process description.

a. Low level.b. High level.c. Medium level.d. None of the above.

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373. You do not have to define ___ and ______ for every process step in SIPOC, because it is a high-level process description.

a. Cost, benefit.b. Input, output.c. Advantages, disadvantages.d. None of the above.

374. SIPOC is used in the ___ phase:

a. Define.b. Measure.c. Control.d. None of the above.

375. Which sequence is followed in CTQ tree building?

a. Need, drivers, CTQ’s.b. Drivers, need, CTQ’s.c. CTQ’s, need, drivers.d. CTQ’s, drivers, need.

376. SIPOC uses a framework applicable to processes of all sizes, even for an entire ____.

a. Organization.b. Department.c. Function.d. All of the above.

377. Which of the following is not a part of the value stream map?

a. Process flow.b. Data on how time is spent.c. Cost of different process steps.d. Information flow.


a. Production center.b. Sales center.c. Control center.d. Orders center.

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a. Telephone communication.b. Order line.c. Employee communication medium.d. None of the above.

380. SIPOC process map is a tool best used for:

a. Identifying the boundaries of the process.b. Drilling down the Y=F(X) process.c. Determining what is currently being provided.d. Assists in determining a project’s timeline.

381. The groups and individuals that result from the SIPOC should be classified into a ___ matrix.

a. Stakeholders.b. Organization.c. Partnership.d. None of the above.


a. Dedicated process.b. Data box.c. Work cell.d. Inventory.


a. External locations.b. Finished service to customer.c. Work cell.d. Dedicated process.

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a. Inventory.b. Supplier.c. Dedicated process.d. Internet.


a. Push arrow.b. Shipments.c. Manual info.d. Electric info.


a. Invalid process.b. Shared process.c. Process improvements.d. Dedicated process.


a. Direction arrow.b. Information arrow.c. Push arrow.d. Time arrow.

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a. Only sales orders.b. Only purchase orders.c. Both sales and purchase orders.d. None of the above.


a. Warehouse.b. Production cell.c. Cross-dock.d. Supplier.


a. Warehouse.b. Production cell.c. Cross-dock.d. Supplier.

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a. Expedited.b. Inventory.c. Production arrow.d. None of the above.


a. Inventory shelf.b. Production cell.c. Data box.d. Supermarket.

393. VOC & CTQ is used during the ___phase to identify the critical ___.

a. Define, measuring points.b. Measure, measuring points.c. Analyze, mistakes.d. None of the above.

394. The general VOC information is translated into ___customer____.

a. Measurable, profit.b. Measurable, requirements.c. Important, requirements.d. None of the above.

395. CTQ’s should contain no ____and should be measurable.

a. Choices.b. Defects.c. Solutions.d. All of the above.

396. Which of the following are steps in CTQ tree?

a. Identify critical needs, identify quality drivers, identify cost savings.b. Identify critical needs, identify quality drivers, identify performance requirements.c. Identify depending variables, identify independent variables, identify reduced impact.d. None of the above.

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397. In CTQ, you have to identify needs, which are ____to, your product.

a. Less important.b. Cost increasing.c. Price elastic.d. Critical.

398. After identifying the critical needs, you need to identify the ____.

a. Quality drivers.b. Performance requirements.c. Cost structure of these of these critical needs.d. None of the above.

399. Once you have completed a CTQ tree for each critical need, you will have a list of all ____ ____that you must meet to deliver a high quality product/service.

a. Identified demands.b. Identified critical needs.c. Measurable costs.d. Measurable requirements.

400. CTQ’s are based on ____features, which are measurable.

a. Product/service.b. Production level.c. Price.d. Cost.


a. Info loop.b. Material pull.c. Process circle.d. Manual info.


a. FIFO lane.b. LIFO lane.c. Production lane.d. Moving lane.

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a. Inventory.b. Production box.c. Safety stock.d. None of the above.


a. Internal shipment.b. External shipment.c. Production lane.d. Safety stock.


a. Production control.b. People in production control.c. Change in production control.d. New production control team.


a. Electronic information.b. Manual information.c. Only customer information.d. Only supplier information.

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a. Electronic information.b. Manual information.c. Only customer information.d. Only supplier information.


a. Production control.b. Production cell.c. Production Kanban.d. Production order.


a. Withdrawal kanban.b. Waiting time.c. Waiting inventory.d. Withdrawal box.

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a. Supplier signal.b. Production Kanban.c. Withdrawal Kanban.d. Signal Kanban.


a. Signal kanban.b. Production Kanban.c. Kanban box.d. Withdrawal Kanban.


a. Parallel pull.b. Sequenced pull.c. Linear pull.d. Binary pull.


a. Load leveling.b. Sequenced pull.c. Kanban box.d. Signal Kanban.

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a. ITP.b. MRP/ERP.c. Production cell.d. HTTP.


a. Verbal information.b. Worker.c. Air flight.d. Orders.


a. Ideas.b. Kaizen burst.c. Verbal information.d. Operator.

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a. Ideas.b. Kaizen burst.c. Verbal information.d. Operator.


a. Ideas.b. Other information.c. Verbal information.d. Operator information.


a. Production levels.b. Time line.c. Process efficiency.d. Operator.


a. Rail shipments.b. Road shipments.c. Air shipments.d. Delivery.

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a. Rail shipments.b. Road shipments.c. Air shipments.d. Delivery.


a. Expedited.b. Inventory.c. Production arrow.d. None of the above.

423. Agility is an appropriate balance between efficiency and flexibility.

a. True.b. False.

424. Processes and practices:

1. A process is a series of actions or operations supported by structured information.2. Processes are activities that are generally repetitive, well defined, routine, controllable and standardized.3. Practices are non-routine, highly variable, loosely defined and require a degree of judgment and experience to carry out.

a. None of the above is correct.b. 1 and 2 are correct.c. 1 and 3 are correct.d. 2 and 3 are correct.e. All of the above are correct.

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425. Mass customization is:

1. An optimal balance between process and practice.2. The ability to produce products and services with the flexibility to meet a wide range of customer needs while maintaining mass produc-tion efficiency.

a. None of the above is correct.b. 1 is correct.c. 2 is correct.d. Both are correct.

426. CMM:

1. Means Capability Maturity Model.2. Consists of 5 steps.3. The 5 steps are: unpredictable, loosely defined, standardized, quantitatively managed, continuously improving.

a. None of the above is correct.b. 1 is correct.c. 2 is correct.d. 3 is correct.e. All are correct.

427. The basic steps of benchmarking include:

1. Understand your current processes in terms of effectiveness and maturity.2. Set your focus by determining what business process you are investigating.3. Identify what organizations and industries have similar processes and are potential leaders.4. Research and contact leading companies to identify best practices and performance metrics.5. Collaborate with these organizations to share best practice information.6. Identify gaps and opportunities for improvement, feed these ideas as suggestions and potential countermeasures into the kaizen process.7. Implement improved business practices with realistic metrics, goals and targets applying PDCA.

a. One or more steps are missing.b. There are too many steps.c. The steps are in the wrong order.d. All steps are correct.

428. Process measures are leading indicators, which focus on tactical activities that directly or indirectly influence results measures.

a. False.b. True.

429. Wait time and transaction accuracy, on-time delivery, first pass quality, cycle time and accurate and speedy check out are:

a. Result measures.b. Process measures.c. KPI’s.d. None of the above.

430. Banking experience, customer satisfaction, warranty claims, patient experience and retail experience are:

a. Result measures.b. Process measures.c. KPI’s.d. None of the above.

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431. Processes can be separated into two categories: supporting and innovating:

a. True.b. False.

432. Which statement(s) is/are correct?

1. Supporting processes are those that are necessary for the business to operate, but do not create differentiation in the eyes of the customer.2. Innovating processes reinvent the business and establish differentiation in the eyes of the customer.


433. Which statement(s) is/are correct?

1. Mass customization is the sweet spot of Agility.2. Mass customization consists of MTO and ATO.

a. Both are correct.b. 1 is correct.c. 2 is correct.d. None of the above is correct.

434. Mass customization is called a mixed model production:

a. False.b. True.

435. Kanban has several purposes:

1. Triggers work only when ordered by customers.2. Indicates the specific work to be done.3. Controls the amount of work in process.4. Buffers interruptions.5. Orchestrates the pace of work.

a. One item is missing.b. One item is not correct.c. One item is too much.d. All items are correct.

436. Heijunka is level scheduling:

a. True.b. False.

437. When demand exceeds capacity there are only three choices:

1. Do nothing.2. Add capacity.3. Manage demand and balance capacity with a disciplined decision-making process.

a. None of the above is correct.b. 1 and 2 are correct.c. 1 and 3 are correct.d. 2 and 3 are correct.e. All of the above are correct.

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438. The distinction between value streams and IT projects are:

1. Value streams are relatively permanent groups of resources, often physically or virtually co-located, that perform similar ongoing activi-ties.2. IT projects are teams temporarily assembled for a specific event or deliverable.

a. 1 is correct.b. 2 is correct.c. None of the above is correct.d. Both are correct.

439. The necessary behaviors for an effective lean management system are:

1. Leader standard work.2. Visual controls.3. Daily accountability.4. Discipline.

a. 1 and 3 are correct.b. 2 and 4 are correct.c. None of the above is correct.d. All of the above are correct.

440. The obeya room is a war room:

a. True.b. False.

441. The three levels of performance measurement dashboards that work together to support a healthy environment for continuous improvement are:

1. Operational dashboards.2. Tactical dashboards and scorecards.3. Strategic scorecards.

a. None of the above is correct.b. 2 is correct.c. 1 & 3 are correct.d. All are correct.

442. The purpose of the operational, tactical and strategic boards are respectively to monitor operations, measure progress and execu-te strategy:

a. True.b. False.

443. The scopes of the operational, tactical and strategic boards are respectively operational, departmental and enterprise:

a. True.b. False.

444. The emphasis of the operational, tactical and strategic boards is respectively management, analysis and monitoring:

a. True.b. False.

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445. The two dimensions of alignment are vertical and horizontal:

a. True.b. False.

446. Catchball is an iterative communications process:

a. True.b. False.

447. The strategic level of the strategy deployment system focuses on:

1. Long term strategy.2. Midterm strategy.3. Kaikaku.4. Annual hoshin plan.

a. None of the above is correct.b. 1, 3 and 4 are correct.c. 2 is correct.d. All of the above are correct.

448. The tactical level of the strategy deployment system focuses on:

1. Value streams.2. Divisions.3. Business units.4. Departments.

a. None of the above is correct.b. 1, 3 and 4 are correct.c. 2 is correct.d. All of the above are correct.

449. The operational level of the strategy deployment system focuses on:

1. Supporting processes.2. Projects.3. Kaizen.

a. None of the above is correct.b. 1 and 3 are correct.c. 2 is correct.d. All of the above are correct.

450. The overspecialization and concentration of shared resources can cause:

1. Flow interruptions.2. Risk of excessive dependence.3. Communication breakdowns.4. Tendency for specialists to overemphasize on technical issues.

a. None of the above is correct.b. 1 and 3 are correct.c. 2 is correct.d. All of the above are correct.

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451. The ITIL version 3 service lifecycle consists of the next stages:

1. Service strategy.2. Service design.3. Service transition.4. Service operation.5. Continuous service improvement.

a. Stages are incomplete.b. Stages are correct.c. There are too many stages.d. Stages are in wrong order.

452. MTBF:

1. Is mean time between failures.2. Is the average time between service interruptions.3. Is commonly used to measure hardware failure, but it can be equally effective with service failure.

a. All are correct.b. None of the above is correct.c. 1 and 3 are correct.d. 2 is correct.

453. MTTR:

1. Is mean time to repair.2. Is the average time to restore a service after an interruption.

a. All are correct.b. None of the above is correct.c. 1 is correct.d. 2 is correct.

454. The steps in the traditional waterfall approach are:

1. Requirements.2. Analysis.3. Design.4. Code.5. Test.6. Deploy.

a. All are correct and in the correct order.b. All are correct but in the wrong order.c. A step is missing.d. There are too many steps.

455. QFD = quality function deployment:

a. True.b. False.

456. Team cadence = velocity = pace = drumbeat = takt time:

a. False.b. True.

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457. The most commonly used Kanban boards in Lean are:

1. Backlog.2. In process.

a. 1 is correct.b. 2 is correct.c. A Kanban board is missing.d. All are correct.

458. Heijunka means level schedule:

a. False.b. True.

459. Which of the next abbreviations are correct:

1. PMI = Project Management Institute.2. PMBOK = Project Management Body of Knowledge.3. PMO = Project Management Office.

a. All are correct.b. 1 and 3 are correct.c. 2 is correct.d. None of the above is correct.

460. The levels of project management are:

1. Portfolio.2. Program.3. Project.

a. 1 and 3 are correct.b. 1 and 2 are correct.c. 2 and 3 are correct.d. All are correct.

461. Portfolio management focuses on ensuring that projects and programs are reviewed to prioritize resource allocation, and that the management of the portfolio is consistent with and aligned to organizational strategies.

a. True.b. False.

462. A program is a group of related projects managed in a coordinated way to obtain benefits and control not available from mana-ging them individually:

a. False.b. True.

463. When project managers are assigned to a PMO:

1. There is consistency of PM practices.2. There is localized demand management.3. There is central control of PM resources.


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464. When project managers are assigned to business units:

1. There is sharing of enterprise best practices.2. There is deeper knowledge of the business.3. There is access to coaching and support.


465. A project is a temporary endeavor undertaken to create a unique product, service or result.

a. True.b. False.

466. Project management is defined as the application of knowledge, skills, tools and techniques to project activities to meet project requirements:

a. False.b. True.

467. The phases of project management are:

1. Initiate.2. Plan.3. Execute.4. Monitor and control.5. Close.

a. A phase is missing.b. There are too many phases.c. All are correct but in the wrong order.d. All are correct and in the correct order.

468. Project management skills include:

1. Control/stability.2. Requirements management.3. Resource/change management.4. Discovery/flexibility.


469. Process improvement skills include:

1. A3 creation and maintenance with team.2. Value stream mapping.3. Team based problem solving (PDCA or DMAIC).4. Project planning.


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470. The triple constraints in project management are:

1. Time.2. Resources.3. Cost.4. Stake holders.5. Scope.

a. 1, 2 and 3 are correct.b. 2, 3 and 4 are correct.c. None of the above is correct.d. 3, 4 and 5 are correct.e. 1, 3 and 5 are correct.

471. Obeya is Japanese for big room:

a. True.b. False.

472. The focus of conventional project management is on tactical execution; the focus of lean project management is on strategic alignment/voice of the customer:

a. True.b. False.

473. Agility and repeatability is the emphasis of lean project management, stability is the emphasis of conventional project manage-ment:

a. False.b. True.

474. Which of the following combinations are correct:

1. Traditional PM = Initiate = Lean PDCA = Plan.2. Lean PDCA = Plan = Six Sigma = Measure/Analyze.3.Six Sigma = Improve = LSS Tools = Micro PDCA.

a. None of the above is correct.b. 1 is correct.c. 2 and 3 are correct.d. All of the above are correct.

475. Hansei is Japanese for mindfulness or critical self-reflection:

a. True.b. False.

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476. Which of the next essential management systems guide the lean enterprise transformation:

1. Strategy deployment.2. Strategic planning.3. Demand management.4. Business process management.5. Project-, program-, portfolio management.

a. All of the above.b. None of the above.c. All except 2.d. A system is missing.

477. Governance is the collective set of procedures, policies, roles and responsibilities, and organizational structures required to sup-port an effective decision-making process:

a. True.b. False.

478. The IT archetypes are:

1. Utility providers.2. Process optimizers.3. Revenue enablers.

a. None of the above.b. All of the above.c. One archetype is missing.d. 1 and 3.

479. If people and process are not balanced the result is frustration and inefficiency and high cost of operation:

a. False.b. True.

480. If people and technology are not balanced the result is automated chaos and confusion and poor customer service:

a. True.b. False.

481. The stages of the lean IT implementation roadmap are:

1. Strategy.2. Planning.3. Execution.

a. None of the above is correct.b. 1 and 3 are correct.c. 2 is correct.d. All are correct.

482. The strategy stage starts with Establish Leadership Vision and Consensus, followed by Articulate Strategic Intent and Drivers:

a. True.b. False.

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483. The steps in the Planning stage are:

1. Define and communicate the plan.2. Build a lean leadership team.3. Create a basic toolkit.4. Launch pilot kaizen projects.5. Asses key enterprise value streams.

a. All are wrong.b. All are correct.c. 1, 2, 3 and 5 are correct.d. 1, 3 and 5 are correct.

484. The planning stage is equal to the P of PDCA:

a. False.b. True.

485. The execution stage is equal to DCA of PDCA:

a. True.b. False.

486. The execution stage of the roadmap has the following steps:

1. Launch pilot kaizen projects.2. Invest in enterprise wide infrastructure.3. Measure results, asses understanding and buy-in.4. Consolidate gains and build momentum.

a. All are correct, but in the wrong order.b. None of the above is correct.c. All are correct and in the right order.d. A step is missing.

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