Lean Six Sigma Green Belt Certification Core Lean Principles 2 — Questions and Answers
Question 1: Which of the eight wastes in Lean refers to producing more than the customer currently needs?
- Overproduction (Correct answer)
- Waiting
- Excess inventory
- Defects
Correct answer: Overproduction
Overproduction is considered the worst waste because it generates many of the other wastes, such as excess inventory and unnecessary transport.
Question 2: A Lean practitioner observes that workers are idle between process steps due to upstream delays. Which waste does this represent?
- Motion
- Waiting (Correct answer)
- Overprocessing
- Transportation
Correct answer: Waiting
Waiting waste occurs when people, materials, or equipment are idle while waiting for the next step in a process.
Question 3: What does the Lean principle of 'Respect for People' primarily emphasize?
- Reducing headcount to lower costs
- Engaging employees in problem-solving and continuous improvement (Correct answer)
- Giving management final authority on all decisions
- Automating tasks to eliminate human error
Correct answer: Engaging employees in problem-solving and continuous improvement
Respect for People means engaging employees at all levels in identifying problems and developing solutions, leveraging their knowledge and creativity.
Question 4: In Lean, what is the primary purpose of standardized work?
- To limit employee creativity
- To establish a repeatable baseline for continuous improvement (Correct answer)
- To document processes solely for compliance purposes
- To ensure managers can monitor employees more closely
Correct answer: To establish a repeatable baseline for continuous improvement
Standardized work captures the current best-known method as a stable baseline from which improvements can be measured and sustained.
Question 5: Which concept describes the rate at which the customer demands a product or service, used to pace production?
- Cycle time
- Lead time
- Takt time (Correct answer)
- Throughput time
Correct answer: Takt time
Takt time is calculated by dividing available production time by customer demand, setting the heartbeat for the entire value stream.
Question 6: A company redesigns its factory floor so that each workstation is positioned immediately next to the next step in production. Which Lean concept is being applied?
- Just-in-Time replenishment
- Flow (Correct answer)
- Pull system
- Visual management
Correct answer: Flow
Flow means arranging steps so that products move continuously through the value stream without stoppages, queues, or batching.
Question 7: Which waste category encompasses unnecessary movement of people within a workplace, such as walking to retrieve tools stored far away?
- Transportation
- Motion (Correct answer)
- Waiting
- Excess inventory
Correct answer: Motion
Motion waste refers to unnecessary physical movement of people, distinct from transportation waste which involves moving materials or products.
Lean Six Sigma Green Belt Certification Core Lean Principles 2
Which of the eight wastes in Lean refers to producing more than the customer currently needs?