FREE Lean Six Sigma Green Belt Lean Principles and Waste Questions and Answers

Question 1

A hospital pharmacy prepares standard medication packs in large batches at the beginning of the week based on a forecast, even though daily demand varies. Many packs are not used by their expiration date and must be discarded. This practice is a primary example of which type of waste?

Accepted Answer

Overproduction

Answer

Overproduction is the waste of producing more than, sooner than, or faster than is required by the next process or the customer. Making packs based on a forecast instead of actual, immediate demand leads to excess inventory that expires and becomes waste.

Question 2

From a Lean perspective, which of the following BEST defines a 'value-added' activity?

Accepted Answer

Any activity that transforms the product or service and the customer is willing to pay for.

Answer

The core principle of Lean is to define value from the customer's perspective. A value-added activity must meet three criteria: it transforms the product or service, the customer is willing to pay for it, and it's done right the first time.

Question 3

A company transitions from a system where inventory is produced based on sales forecasts to a system where production is triggered only by an actual customer order. This change represents a shift towards which fundamental Lean principle?

Accepted Answer

Pull System

Answer

A Pull system is one where work is only initiated when there is demand from a downstream process, ultimately driven by the customer. This contrasts with a 'Push' system, which produces goods based on forecasts and pushes them to the market.

Question 4

A manufacturing company implements a new process but fails to train machine operators on its full capabilities or solicit their ideas for improvement. As a result, the process is inefficient and prone to errors. This situation highlights which of the eight wastes?

Accepted Answer

Non-Utilized Talent

Answer

The waste of Non-Utilized Talent refers to the failure to leverage the skills, knowledge, and creativity of the workforce. By not properly training or involving the operators, the company is wasting their potential contributions to process efficiency and quality.

Question 5

The rate at which products need to be completed to meet customer demand is one every 20 minutes. The total time from when an order is placed to when it is delivered is 4 days. The actual time spent working on one unit is 3 hours. Which of these represents the Takt Time?

Accepted Answer

20 minutes

Answer

Takt time is the rate at which a finished product needs to be completed to meet customer demand. It's the 'heartbeat' of the production system. In this scenario, that rate is explicitly stated as one every 20 minutes. The 4 days is Lead Time, and the 3 hours is Cycle Time.

Lean Six Sigma Green Belt Certification Practice Test

Lean Six Sigma Green Belt Certification Practice Test

FREE Lean Six Sigma Green Belt Lean Principles and Waste Questions and Answers