Practice Test Geeks(APICS) American Production and Inventory Control Society Certified Practice Test
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Lean Manufacturing & Continuous Improvement Flashcards

7 cards from real APICS practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

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  1. What is the DMAIC framework primarily associated with?

    Answer: Six Sigma process improvement

    DMAIC (Define, Measure, Analyze, Improve, Control) is the structured problem-solving methodology used in Six Sigma projects to improve existing processes.

  2. Which lean concept describes the practice of stopping production immediately when a defect is detected to prevent further defective output?

    Answer: Jidoka

    Jidoka (autonomation) is the principle of automatically stopping a machine or line when a defect is detected, preventing defects from passing to the next process.

  3. In the Theory of Constraints (TOC), what is the first step in the Five Focusing Steps?

    Answer: Identify the system's constraint

    The first step in TOC's Five Focusing Steps is to identify the system's constraint — the single limiting factor that prevents the system from achieving higher performance.

  4. What does 'Genchi Genbutsu' mean in the context of lean and the Toyota Way?

    Answer: Go and see for yourself at the actual place

    Genchi Genbutsu means 'go and see for yourself' — the practice of personally observing conditions at the actual place of work (gemba) rather than relying solely on reports.

  5. Which lean metric measures the ratio of value-added time to total lead time through a process?

    Answer: Process cycle efficiency (PCE)

    Process Cycle Efficiency (PCE) is calculated as value-added time divided by total lead time, indicating what percentage of total elapsed time actually adds value for the customer.

  6. What is the primary focus of Total Productive Maintenance (TPM)?

    Answer: Involving all employees in maintaining equipment to maximize OEE

    TPM focuses on involving all employees — especially operators — in maintaining equipment to maximize its effectiveness, targeting zero breakdowns, zero defects, and zero accidents.

  7. In lean supply chain management, what is the concept of 'pull' production?

    Answer: Producing goods only in response to actual customer demand signals

    Pull production triggers manufacturing only when actual downstream demand or a replenishment signal occurs, preventing overproduction and reducing inventory throughout the supply chain.