LMC Assessment & Evaluation Methods 3 — Questions and Answers
Question 1: Which lean assessment approach involves timing multiple cycle observations to establish a reliable baseline?
- Time study with multiple cycles averaged (Correct answer)
- Single-point work sampling
- Voice of the customer survey
- Cause-and-effect matrix
Correct answer: Time study with multiple cycles averaged
Averaging multiple timed cycles reduces variability and gives a statistically reliable baseline for process evaluation.
Question 2: In a lean maturity model, a score of 'Level 2 – Reactive' typically indicates:
- Lean tools are applied enterprise-wide with sustained results
- Problems are addressed only after they cause visible disruption (Correct answer)
- Continuous improvement is embedded in daily management routines
- Leadership actively mentors lean practitioners at all levels
Correct answer: Problems are addressed only after they cause visible disruption
Level 2 organizations use lean tools reactively in response to crises rather than proactively or systematically.
Question 3: What does a spaghetti diagram evaluate in a lean assessment?
- Frequency of defects across product lines
- Physical movement paths of people or materials in a workspace (Correct answer)
- Sequence of value-added steps in a process
- Volume of customer complaints over time
Correct answer: Physical movement paths of people or materials in a workspace
A spaghetti diagram maps actual movement paths to reveal excessive travel distance and motion waste.
Question 4: Which of the following is the MOST important input when prioritizing improvement opportunities identified during a lean assessment?
- Manager's personal preference for certain tools
- Impact on customer value versus effort to implement (Correct answer)
- Number of employees affected by the change
- Availability of consulting support
Correct answer: Impact on customer value versus effort to implement
Lean prioritization should weigh customer value impact against implementation effort to maximize return on improvement energy.
Question 5: A value stream map shows a large 'push' arrow between two production steps. This symbol indicates:
- A pull kanban signal connects those steps
- Material is pushed without a downstream demand signal (Correct answer)
- A supermarket buffer is controlling flow
- The steps are perfectly balanced to takt time
Correct answer: Material is pushed without a downstream demand signal
A push arrow in a VSM indicates overproduction waste where upstream output is not triggered by downstream need.
Question 6: When evaluating changeover time as part of a SMED assessment, internal activities are defined as:
- Tasks that can be done while the machine is still running
- Tasks that can only be performed when the machine is stopped (Correct answer)
- Administrative paperwork completed before the run
- Quality checks performed after the first good piece
Correct answer: Tasks that can only be performed when the machine is stopped
Internal activities require the machine to be stopped, making them the primary target for SMED conversion to external tasks.
Question 7: Which statistical tool is used in lean to determine if the variation in a process output is due to common cause or special cause?
- Pareto chart
- Histogram
- Control chart (SPC) (Correct answer)
- Scatter plot
Correct answer: Control chart (SPC)
Control charts distinguish between natural common-cause variation and assignable special-cause variation using control limits.
LMC Assessment & Evaluation Methods 3
Which lean assessment approach involves timing multiple cycle observations to establish a reliable baseline?