LMC Lean Implementation and Continuous Improvement 2

Question 1

A lean team discovers that 40% of defects originate in a single process step. Which tool is BEST suited to prioritize root cause investigation?

Accepted Answer

Pareto chart

Answer

A Pareto chart ranks defect causes by frequency, revealing the vital few issues (80/20 rule) that drive the majority of problems.

Question 2

During a kaizen event, the team wants to reduce motion waste in an assembly cell. Which technique directly maps worker movement paths?

Accepted Answer

Spaghetti diagram

Answer

A spaghetti diagram traces the actual physical movement of workers or materials, making motion waste visible.

Question 3

Standard work is best described as:

Accepted Answer

The documented current best method that forms the baseline for improvement

Answer

Standard work captures the current best-known method and creates a stable baseline from which continuous improvement can be measured.

Question 4

A plant manager wants to level production output across shifts to match average customer demand. This scheduling approach is called:

Accepted Answer

Heijunka (production leveling)

Answer

Heijunka levels the volume and mix of production over time to reduce overburden, unevenness, and inventory fluctuations.

Question 5

Which lean metric measures the percentage of time a process actually adds value to the product versus total lead time?

Accepted Answer

Process cycle efficiency (PCE)

Answer

Process cycle efficiency (PCE) is calculated as value-added time divided by total lead time, typically less than 5% in traditional manufacturing.

(LMC) Lean Management Certification Practice Test