EXAMPLE LEVEL 1A MCT QUESTIONS PDF

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LCS EXAMPLE LEVEL 1A MCT QUESTIONS ...

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EXAMPLE LEVEL 1A MCT QUESTIONS & ALIGNMENT TO LCS FRAMEWORK 1A LEVEL DESCRIPTOR (LEAN AWARENESS KNOWLEDGE) A1

Origins and evolution of lean thinking (eg Toyota, Ford, Deming, TWI, etc).

A2

Underpinning and related concepts (eg PDCA, scientific method, continuous improvement, systems thinking, etc)

A3

Key lean principles (eg Womack & Jones, Spear & Bowen etc); value, value stream, flow, pull, perfection

A4

Wastes (identification, categorisation etc); value adding, necessary non-value adding and non-value adding activities; value demand/failure demand

A5

Awareness of the human and strategic dimensions of lean thinking (eg change, engagement, policy deployment, etc)

QUESTION INSTRUCTIONS Each question should have clear instructions (eg ‘select one answer only’, ‘write an answer for each number’, ‘circle the correct answer(s)’, etc) and indicate the number of marks for each question, including any partial marking (if applicable) and time allowance.

EXAMPLE QUESTIONS The right hand column indicates the LCS 1a level descriptor to which the question relates. Once the test has been finalised, the number of question linked to each can be totalled to indicate question spread (see table at end of document). Correct answers are highlighted in yellow. #

Questions

Answer Options

1

Lean thinking’s fifth principle (Womack & Jones) is concerned with which of the following?

a) The quality or condition of being perfect

LCS 1a Alignment A3

b) The endless pursuit for perfection c) The act or process of perfect d) The state of being without a flaw or defect e) The act of making something perfect

2

What are the ‘seven wastes’ of the Toyota Production System? (to be listed)

a) Transport

A4

b) Inventory c) Motion

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Questions

Answer Options

LCS 1a Alignment

d) Waiting

3

3 marks if all correct

e) Overproduction

2 if six correct

f) Over processing

1 if five correct

g) Defects

A value stream shows all activities from order to what?

a) Consumption

A3

b) Production c) Delivery d) Customer service e) Storage

4

What is the correct order of Womack & Jones’ lean principles?

a) Pursue Perfection (5)

A3

b) Create Flow (3) c) Identify the Value Stream (2)

Place a number between 1 – 5 against each principle

5

PDCA is a systematic problem solving process. Match the letter with the action.

d) Specify Customer Value (1) e) Create Pull (4)

a) Measure improvement. (C)

A2

b) Implement as standard.(A) c) Identify root cause. (P)

Place one of the letters P D C A next to each action 6

Necessary Non-Value Adding is a term used to describe an activity that is what?

d) Trial solution. (D)

a) Important in delivering value to customers.

A3, A4

b) Part of the operation’s support function. c) Required by current state but Is difficult to remove today. d) Ready for immediate removal.

7

8

Fill in the missing word for Rule One of Spear & Bowen’s DNA of the Toyota Production System: “All work shall be highly xxxx as to content, sequence, timing and outcome.”

A successful lean implementation should

a) Sorted

A2, A3

b) Specified c) Standardised d) Synchronised

a) Reduce headcount

A2,A3

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Questions

Answer Options

primarily achieve which one of the following?

b) Improve profitability

LCS 1a Alignment

c) Release capacity d) Increase stock value

9

10

Lean is said to be about reducing Muda, Mura and Muri. Which one of the following is not a translation of one of these?

f) Waste

A ‘contingent’ approach to lean thinking implies what?

a) You adopt a prescriptive approach to lean implementation

A3

g) Overburden h) Unevenness i) Overstocking

A2

b) You adapt your implementation approach depending on your particular circumstances c) You do not make details plans but implement in an organic way d) You focus on using the classic tools of the Toyota Production System 11

Womack has an abbreviated definition of lean, which is ‘Lean = purpose + process + what’?

a) Planet

A3

b) Policy c) People d) Practice

12

Policy deployment primarily aims to achieve which of the following?

a) The control of workers actions and performance

A5

b) Ensuring business targets are met c) Alignment of actions with strategic objectives d) To formulate an effective strategy.

13

Complete this quote by Henry Ford: “every process should be regarded as what”.

a) Standardised

A1

b) Innovative c) Experimental d) Experiential

14

According to Spear & Bowen, any improvement must be made in accordance with what, under the guidance of a

a) Scientific management

A3

b) Simplified communications c) Standard operations

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15

Questions

Answer Options

teacher, at the lowest possible level in the organization?

d) Scientific method

What is Takt time?

a) The time it takes to make a standard product

LCS 1a Alignment

A3

b) The rate that components need to be supplied to the production line c) The synchronisation of operations to customer demand d) The time of equipment changeover 16

Policy deployment primarily aims to achieve which of the following?

a) The control of workers actions and performance

A5

b) Ensuring business targets are met c) Alignment of actions with strategic objectives d) To formulate an effective strategy.

17

The Pareto principle is often referred to as what?

a) The 80:20 rule

A2

b) The 95:5 rule c) The law of the vital many d) The principle of factor disparity

18

Complete the quote by W Edwards Deming: “In God we trust. All others must bring xxxx”

a) Solutions

A1

b) Plans c) Data d) Methods

19

In lean thinking terms perfection is which one of the following

a) The endless pursuit to be perfect.

A3

b) The quality or condition of being perfect. c) The act or process of perfect. d) The state of being without a flaw or defect. e) The act of making something perfect.

20

A value stream shows all activities from order to what?

a) Consumption

A3

b) Production c) Delivery d) Customer service e) Storage

21

The opposite of Single Piece Flow is

a) A chaotic system

A3

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Questions

Answer Options

LCS 1a Alignment

b) Multiple piece flow c) Batch and queue production d) Shared services 22

Which is considered the worst of Taiichi Ohno’s seven wastes?

a) Transport

A4

b) Inventory c) Motion d) Waiting e) Overproduction f) Over processing g) Defects

23

From whose perspective should value be identified in a lean organisation?

a) Stakeholders

A3

b) Customers c) Suppliers d) Shareholders

24

Who in a company should own standard processes?

a) Management

A5

b) Engineering c) Front line employees d) Quality control

25

In a service environment, pull should be based on what?

a) TAKT time

A3

b) Kanban c) Real customer demand d) Service delivery capacity

26

To where should the lean practitioner go in order to learn and discover the facts about work?

j) The warehouse

A2

k) The gemba l) The gamba m) The supply chain

27

In Spear & Bowen’s four rules of the Toyota DNA, any improvement must be made in accordance with what?

a) Standardised processes

A2

b) Reference to customer value c) The scientific method d) Company strategy

28

In a lean process, you should only do what the customer will...

a) Want to stock

A3

b) Want to take delivery of c) Want to pay for

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Questions

Answer Options

LCS 1a Alignment

d) Want to consume 29

Emiliani has stated that ‘real lean’ is a combination of continuous improvement plus what?

a) Focus on the customer

A5

b) Respect for people c) Respect for the process d) Effective problem solving

30

The amount of time taken to complete an operation is called what?

a) Cycle time

A3

b) Takt time c) Lead time d) Just in time

31

Which industrialist is said to have inspired the creation of the Toyota Production System?

a) Jack Welch

A1

b) W Edwards Deming c) Henry Ford d) Karl Benz

32

What is the acronym used to remember the classic seven wastes?

a) TOD WOLD

A4

b) TED WARD c) TIM WOOD d) TOM WENT

33

In services, what is the term used to describe the demand that arises due to a previous fault in operations or service?

a) Non added value demand

A3

b) Failure demand c) Customer complaints demand d) System breakdown demand

34

Womack has an abbreviated definition of lean, which is ‘lean = purpose + process + what’?

a) Planet

A3, A5

b) Policy c) People d) Practice e) Patience

35

36

What term describes the techniques developed in World War II to improve aircraft production that are said to form the foundation of lean thinking? Which of these is not one of Bicheno’s ‘new service wastes’?

a) Total Quality Management

A1

b) Training Within Industry c) Toyota Production System d) Industrial Engineering a) Waste of inappropriate systems

A4

b) Waste of lack of concentration c) Waste of untapped human potential

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Questions

Answer Options

LCS 1a Alignment

d) Waste of excessive information & communication 37

Functionalising processes will most likely result in what?

a) Reduced lead times

A4

b) Improved quality c) Batching of work d) Improved efficiencies

38

The biggest impact on improved flow can be achieved through which one of the following?

a) The use of larger batches

A3

b) The reduction in the space used in the process c) A reduction in inventory held d) The use of smaller batches

39

TAKT time is which one of the following?

a) The rate that stock is replenished

A3

b) The time it takes to complete one cycle c) The speed that the customer pulls d) The rate at which an operator works

40

In which book was the word ‘lean’ first used?

a) The Machine that Changed the World

A1

b) Lean Thinking c) Lean Solutions d) The Toyota Way

41

Which two of the following does value stream mapping aim to depict?

a) People flow

A3

b) Material flow c) Information flow d) Stock flow

42

Which one of the following phrases best summarises the approach underpinning standardisation?

a) Keeping organised

A3

b) A place for everything, everything in its place c) One best way d) Control through discipline

43

Which World War Two operations and training system is said to have inspired Toyota?

a) Business Process Reengineering

A1

b) Total Quality Management c) Six Sigma d) Training Within Industry

44

What does PDCA stand for?

a) Plan

A2

b) Do c) Check d) Act

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LEARNING OUTCOMES COVERAGE CHECK Number of questions addressing each area A1

6

A2

8

A3

23

A4

6

A5

5

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