ASQ Lean Quality Management 2 — Questions and Answers
Question 1: 'Kanban' in a lean system is primarily used to:
- Track employee performance metrics
- Signal the need to produce or replenish items based on actual consumption — a pull signal (Correct answer)
- Document standard operating procedures
- Measure overall equipment effectiveness
Correct answer: Signal the need to produce or replenish items based on actual consumption — a pull signal
Kanban is a visual signaling system that triggers production or replenishment only when needed, supporting a pull-based flow that reduces overproduction and inventory.
Question 2: 'Single-piece flow' (one-piece flow) is preferred in lean because:
- It maximizes machine utilization by running large batches
- It reduces lead time, exposes problems immediately, and improves quality by processing items one at a time (Correct answer)
- It minimizes the need for operator training
- It increases inventory buffer between processes
Correct answer: It reduces lead time, exposes problems immediately, and improves quality by processing items one at a time
Single-piece flow minimizes work-in-process inventory, reduces lead time, and surfaces quality problems immediately since defects can't hide in large batches.
Question 3: Overall Equipment Effectiveness (OEE) is calculated from which three factors?
- Quality, speed, and cost
- Availability, Performance, and Quality (Correct answer)
- Uptime, throughput, and defect rate
- Cycle time, setup time, and downtime
Correct answer: Availability, Performance, and Quality
OEE = Availability × Performance × Quality, providing a comprehensive measure of how effectively manufacturing equipment is being utilized.
Question 4: 'Standard work' in lean refers to:
- The average output of all workers across a shift
- Documented, repeatable procedures that define the current best way to perform a task, used as the baseline for improvement (Correct answer)
- Work performed only by certified operators
- The minimum acceptable quality level for a product
Correct answer: Documented, repeatable procedures that define the current best way to perform a task, used as the baseline for improvement
Standard work captures the optimal sequence, timing, and method for each operation, creating a stable baseline that ensures consistency and provides a foundation for kaizen.
Question 5: In lean, a 'pull system' means:
- Management pulls employees toward production targets
- Downstream processes signal upstream processes to produce only what is needed, when it is needed (Correct answer)
- Products are pulled off the line for random inspection
- Suppliers push inventory into the facility on a schedule
Correct answer: Downstream processes signal upstream processes to produce only what is needed, when it is needed
A pull system produces items only in response to actual demand signals from downstream processes or customers, preventing overproduction and excess inventory.
Question 6: 'SMED' (Single-Minute Exchange of Die) is a technique for:
- Reducing defects in stamping operations
- Drastically reducing equipment changeover and setup time to under 10 minutes (Correct answer)
- Standardizing die specifications across product lines
- Scheduling preventive maintenance on presses
Correct answer: Drastically reducing equipment changeover and setup time to under 10 minutes
SMED, developed by Shigeo Shingo, focuses on converting internal setup activities to external ones and streamlining all setup steps to achieve changeover times under 10 minutes.
ASQ Lean Quality Management 2
'Kanban' in a lean system is primarily used to: