CLL Kaizen & Continuous Improvement Events 2 — Questions and Answers
Question 1: What is the main difference between a Kaizen event and a traditional improvement project?
- A Kaizen event is short, focused, and rapid; a traditional project is longer and broader in scope (Correct answer)
- A Kaizen event requires external consultants; a traditional project uses internal staff
- A Kaizen event focuses only on cost reduction; a traditional project focuses on quality
- A Kaizen event is managed by IT; a traditional project is managed by operations
Correct answer: A Kaizen event is short, focused, and rapid; a traditional project is longer and broader in scope
Kaizen events are compressed, cross-functional workshops designed to produce immediate results, unlike multi-month traditional projects.
Question 2: During a Kaizen event, a '30-day list' is used to track items that:
- Cannot be resolved during the event but need follow-up action (Correct answer)
- Were completed on time during the event
- Require regulatory approval before implementation
- Are out of scope and should be discarded
Correct answer: Cannot be resolved during the event but need follow-up action
The 30-day list captures important improvement ideas or tasks that could not be finished within the event window, ensuring accountability after the event.
Question 3: Which lean concept describes the ideal state where every process step adds value as perceived by the customer?
- Value-added flow (Correct answer)
- Poka-yoke
- Heijunka
- Jidoka
Correct answer: Value-added flow
Value-added flow is the goal where each step in the process transforms the product or service in a way the customer is willing to pay for.
Question 4: A Lean Leader facilitating a Kaizen event observes team members reverting to old habits after the event. The BEST response is to:
- Implement standard work and use regular audits to sustain the improvement (Correct answer)
- Conduct another Kaizen event immediately
- Replace the team members who reverted
- Reduce the scope of the improvement
Correct answer: Implement standard work and use regular audits to sustain the improvement
Standard work documents the new process and audits verify adherence, which are the primary mechanisms for sustaining Kaizen gains.
Question 5: What is 'breakthrough Kaizen' (also known as Kaikaku) distinct from everyday Kaizen?
- It involves radical, large-scale change rather than incremental improvement (Correct answer)
- It is performed only by executives
- It focuses exclusively on administrative processes
- It requires no team involvement
Correct answer: It involves radical, large-scale change rather than incremental improvement
Kaikaku (breakthrough Kaizen) refers to fundamental, radical transformation of a process, whereas everyday Kaizen focuses on small, incremental improvements.
Question 6: In a Kaizen event report-out, what should the team present to leadership?
- Current state, future state, improvements made, results measured, and open action items (Correct answer)
- A financial budget request for the next quarter
- A list of problems that could not be solved
- Competitor benchmarking data
Correct answer: Current state, future state, improvements made, results measured, and open action items
The report-out communicates what was found, what was changed, measurable results achieved, and what still needs follow-up.
Question 7: Which of the following best describes 'continuous flow' as it relates to Kaizen improvement events?
- Processing one piece at a time through sequential steps without queuing between steps (Correct answer)
- Running production 24 hours a day without stopping
- Maintaining maximum inventory at each workstation
- Scheduling batch production in large lot sizes
Correct answer: Processing one piece at a time through sequential steps without queuing between steps
Continuous flow eliminates batching and queuing between process steps so each unit moves immediately to the next step, minimizing lead time.
CLL Kaizen & Continuous Improvement Events 2
What is the main difference between a Kaizen event and a traditional improvement project?