LMC Lean Principles and Foundations 2 — Questions and Answers
Question 1: Which lean principle focuses on delivering value in small, frequent increments rather than large batches?
- Batch processing
- Flow (Correct answer)
- Pull
- Perfection
Correct answer: Flow
Flow is the lean principle of moving work through the value stream smoothly and continuously in small increments to reduce delays and inventory.
Question 2: In lean thinking, 'Muda' refers to which of the following?
- Value-added activity
- Waste (Correct answer)
- Continuous improvement
- Standard work
Correct answer: Waste
Muda is the Japanese term for waste — any activity that consumes resources without adding value for the customer.
Question 3: A company redesigns its assembly line so that each station's output rate matches the customer demand rate. This is an example of applying which lean concept?
- Kanban
- Takt time (Correct answer)
- Kaizen
- 5S
Correct answer: Takt time
Takt time is the rate at which products must be completed to meet customer demand, and aligning production to takt time is a core lean practice.
Question 4: Which of the following best describes the 'Pull' principle in lean?
- Producing goods based on sales forecasts
- Producing goods only when the downstream process signals a need (Correct answer)
- Pushing inventory to meet maximum capacity
- Scheduling production based on supplier availability
Correct answer: Producing goods only when the downstream process signals a need
Pull means production is triggered by actual downstream demand, preventing overproduction and excess inventory.
Question 5: Which lean waste category describes defective products that require rework or scrap?
- Transportation
- Overproduction
- Defects (Correct answer)
- Motion
Correct answer: Defects
Defects is one of the 8 wastes of lean and includes any product or service that does not meet quality requirements, requiring rework or disposal.
Question 6: The concept of 'Genchi Genbutsu' in lean management means:
- Continuous improvement through small steps
- Go and see for yourself at the actual place (Correct answer)
- Respect for people and teamwork
- Eliminating all non-value-added steps
Correct answer: Go and see for yourself at the actual place
Genchi Genbutsu means 'go and see' — lean leaders are expected to observe problems firsthand at the actual workplace rather than relying solely on reports.
Question 7: In a lean value stream, which activities should be maximized?
- Non-value-added activities required by regulation
- Value-added activities (Correct answer)
- Inspection activities
- Storage activities
Correct answer: Value-added activities
Lean aims to maximize value-added activities — those that directly transform a product or service in ways the customer is willing to pay for.
LMC Lean Principles and Foundations 2
Which lean principle focuses on delivering value in small, frequent increments rather than large batches?