APICS Lean Manufacturing & Continuous Improvement 2 — Questions and Answers
Question 1: What does the '5S' methodology stand for in lean manufacturing?
- Sort, Set in order, Shine, Standardize, Sustain (Correct answer)
- Schedule, Sequence, Synchronize, Stabilize, Sustain
- Select, Separate, Store, Standardize, Share
- Speed, Safety, Service, System, Sustain
Correct answer: Sort, Set in order, Shine, Standardize, Sustain
5S stands for Sort, Set in order, Shine, Standardize, and Sustain — a workplace organization method that creates a clean, efficient, and safe working environment.
Question 2: Which metric measures the percentage of time a machine is producing quality parts when it is scheduled to run?
- Throughput rate
- Cycle time efficiency
- Overall Equipment Effectiveness (OEE) (Correct answer)
- Capacity utilization rate
Correct answer: Overall Equipment Effectiveness (OEE)
Overall Equipment Effectiveness (OEE) combines availability, performance, and quality metrics to measure how effectively a machine produces good parts during scheduled production time.
Question 3: In lean terminology, what is 'Poka-Yoke'?
- A type of visual management board
- An error-proofing device or technique that prevents defects (Correct answer)
- A Japanese term for continuous improvement
- A method for calculating takt time
Correct answer: An error-proofing device or technique that prevents defects
Poka-Yoke refers to error-proofing mechanisms or techniques designed to prevent mistakes from occurring or to immediately detect them when they do.
Question 4: What is the main objective of SMED (Single-Minute Exchange of Die)?
- To reduce machine downtime caused by breakdowns
- To reduce setup and changeover time to under ten minutes (Correct answer)
- To standardize die specifications across all machines
- To eliminate the need for machine operators
Correct answer: To reduce setup and changeover time to under ten minutes
SMED aims to reduce equipment setup and changeover time to single-digit minutes (under 10 minutes), enabling smaller batch sizes and greater production flexibility.
Question 5: Which of the eight wastes (DOWNTIME) in lean refers to moving products or materials without adding value?
- Overproduction
- Non-utilized talent
- Transportation (Correct answer)
- Inventory
Correct answer: Transportation
Transportation waste refers to unnecessary movement of materials or products between locations, which consumes resources and time without adding value to the product.
Question 6: What is a 'Kaizen event' or 'Kaizen blitz'?
- A long-term strategic planning session for lean implementation
- A focused, short-duration team activity to rapidly improve a specific process (Correct answer)
- An annual review of lean metrics and performance
- A training program for new lean practitioners
Correct answer: A focused, short-duration team activity to rapidly improve a specific process
A Kaizen event (or blitz) is an intensive, focused improvement activity typically lasting three to five days where a cross-functional team rapidly improves a specific process.
Question 7: In lean manufacturing, what is the purpose of 'Heijunka' (production leveling)?
- To maximize machine utilization by running at full capacity
- To smooth production by distributing mix and volume evenly over time (Correct answer)
- To prioritize orders based on customer urgency
- To synchronize supplier deliveries with production schedules
Correct answer: To smooth production by distributing mix and volume evenly over time
Heijunka levels production by spreading the mix and volume of work evenly over a time period, reducing unevenness (Mura) and the need for large inventories or rapid resource changes.
APICS Lean Manufacturing & Continuous Improvement 2
What does the '5S' methodology stand for in lean manufacturing?