Lean Six Sigma Green Belt Certification Lean Six Sigma Green Belt Lean Principles and Waste 1

Question 1

An assembly line worker must stop production for 20 minutes each shift while waiting for a parts delivery from an upstream supplier. Which of the 8 Lean wastes does this scenario most directly illustrate?

Accepted Answer

Waiting

Answer

Waiting waste occurs whenever people, machines, or materials are idle between process steps. The worker is not adding any value during those 20 minutes, making this a textbook example of waiting waste.

Question 2

Which of the following activities is considered value-added in a Lean process?

Accepted Answer

Machining a component to customer-specified dimensions

Answer

A value-added activity must (1) physically transform the product or service, (2) be done correctly the first time, and (3) be something the customer is willing to pay for. Only machining to customer specifications satisfies all three criteria.

Question 3

A quality team applies three coats of paint to a product when the customer specification requires only one coat for adequate protection. This is an example of which Lean waste?

Accepted Answer

Overprocessing

Answer

Overprocessing waste occurs when more effort, precision, or quality is applied than the customer actually requires. The extra paint coats consume resources without adding customer-recognized value.

Question 4

A logistics company employs data analysts in manual sorting roles, never utilizing their statistical expertise. Which of the 8 Lean wastes does this represent?

Accepted Answer

Non-utilized talent

Answer

Non-utilized talent (also called Skills waste) occurs when employees' knowledge, creativity, or specialized skills are not leveraged. It was added as the 8th waste when Lean expanded beyond the original 7 identified by Toyota.

Question 5

A facility operates 8 hours per day with 30 minutes of scheduled breaks. Customer demand is 300 units per day. What is the takt time?

Accepted Answer

1.5 minutes per unit

Answer

Takt time = Available production time ÷ Customer demand. Available time = (8 × 60) − 30 = 450 minutes. Takt time = 450 ÷ 300 = 1.5 minutes per unit. This is the pace at which production must flow to meet demand.

Lean Six Sigma Green Belt Certification Practice Test

Lean Six Sigma Green Belt Certification Practice Test

Lean Six Sigma Green Belt Certification Lean Six Sigma Green Belt Lean Principles and Waste 1