Lean Six Sigma Green Belt Core Lean Principles Questions and Answers

Question 1

A team in a manufacturing plant observes that an operator must walk 100 feet to a separate building to retrieve a specific tool for a 5-minute task, and then walk back.
This entire trip adds 10 minutes to the overall process time for each unit.
This activity is a classic example of which of the 8 Wastes of Lean?

Accepted Answer

Motion

Answer

Transportation

Answer

Overproduction

Answer

Waiting

Question 2

A software development company adds a new, complex reporting feature that was not requested by customers. The development team believes it will be useful, but post-launch data shows that less than 1% of users ever access it. From a core Lean perspective, how is the effort spent on this feature best described?

Accepted Answer

A non-value-adding activity (waste)

Answer

A business-required activity

Answer

A value-adding activity

Answer

A necessary but non-value-adding activity

Question 3

Which of the following scenarios best illustrates the Lean principle of 'Flow'?

Accepted Answer

A patient in a clinic is registered, immediately sees a nurse for triage, and is then placed directly into an examination room to see a doctor without returning to the waiting room.

Answer

Producing large batches of a product based on a quarterly sales forecast to minimize machine setup time.

Answer

An assembly line where each station has a large buffer of inventory to ensure it never has to wait for parts from the previous station.

Answer

Holding a weekly meeting to review production numbers and identify which departments are behind schedule.

Question 4

A custom cabinet maker waits to order wood and begin building a kitchen island until after a customer has signed the contract and approved the design. This practice is a direct application of which core Lean principle?

Accepted Answer

Pull

Answer

Perfection (Kaizen)

Answer

Value Stream Mapping

Answer

Flow

Question 5

What is the PRIMARY purpose of creating a Value Stream Map (VSM) in a Lean initiative?

Accepted Answer

To identify all process steps and, most importantly, to visualize the sources of waste and delay that disrupt flow.

Answer

To serve as a detailed work instruction manual for new employees.

Answer

To calculate the exact financial cost and profit margin for a product.

Answer

To formally document which employees are responsible for each step in a process.

Question 6

A team has just successfully improved a process, reducing the lead time by 50%. During a follow-up meeting, the team leader states, 'This is a great achievement, but now we must look for the next small improvement we can make.' This mindset is a direct reflection of which Lean principle?

Accepted Answer

Perfection (Kaizen)

Answer

Flow

Answer

Pull

Answer

Value