2019-01-02Lean Yellow Belt Exam This exam consists of 50 questions total. Each question has one correct or best answer. Do NOT use the browser buttons (<>) because it will reset the exam and you need to start again. Make sure your email is correctly entered, so you can receive your score. Time for the exam is 1 hour at 1-minute per question = 50 minutes for exam + 10 minutes buffer. Good luck! Fair-Play Rules: I will not cheat I will not discuss with others I will not take notes or pictures By clicking NEXT, you agree to those rules. If you cannot commit, please leave the class. NameEmail Company (?) Select CompanyABBAkzoNobelArtesanASAPIAutolivÅlöDaimlerEltekFischer&PartnerFischer&PartnerFrankeGivaudanGlobalFoundriesHexpolIdeal StandardITESMKlosterfrauKvitebjørn VarmeLandis+GyrLeanmap LVSMercedes BenzNavicoNespressoNoricanNorsk GjenvinningNorthStar Battery SandvikSanta CasaSPTechtronicTresuTrioplanexTrioplastVaudWheelabratorWrist Add New Country Select CountryArgentinaAustraliaAustriaBelgiumBrazilCanadaChileChinaColombiaCroatiaCyprusCzech RepublicDenmarkEgyptEstoniaFinlandFranceGermanyGreeceHong KongHungaryIcelandIndiaIndonesiaIranIrelandIsraelItalyJapanLatviaLiechtensteinLithuaniaLuxembourgMaltaMexicoNetherlandsNew ZealandNorwayOTHER (not listed)ParaguayPolandPortugalQatarRomaniaRussiaSaudi ArabiaSingaporeSouth KoreaSpainSwedenSwitzerlandTaiwanThailandTurkeyUnited Arab EmiratesUnited KingdomUnited StatesUruguayVenezuela 1. Jessica is entering customer orders. But one order exceeds current capability. She presses the Help button to get assistance from her manager. How is this device called? Kanban Andon Kaizen Poka-Yoke Muri Gemba Jidoka2. Grace is checking invoices. After one week, she delivers a large stack of validated invoices to the accounting department for payment. How is such workflow called? Stack-and-go FIFO Just-in-time Continuous flow Batch-and-queue3. Laura locates operators and equipment (required for the process) into one room, so people can work hand-in-hand with minimal motion. How is such arrangement called? Team Office Process village Cell Group4. Which condition is NOT a characteristic of Continuous Flow? Work arranged in sequence Pushing items to next station First in, first out Rapid detection of defects Lean way of processing5. Which is NOT an example of FIFO? Pepper mill Conveyor belt Scooping from top of jar Customers waiting in line Answering oldest email first6. Harry wants his car clean and dry. He drives to the car-wash. It takes 1 minute for paying, 2 minutes for washing, 1 minute for dry-blowing. After this automated process, an operator is finishing the car by wiping lights and mirrors, which takes 1 minute. What is the Total Cycle Time in minutes? 1 2 3 4 57. For the same car-wash example, what is the Operator Cycle Time in minutes? 1 2 3 4 58. For the same car-wash example, what is the Value-Creating Time in minutes? 1 2 3 4 59. For the same car-wash example, what is the Machine Cycle Time in minutes? 1 2 3 4 510. Each car-wash takes 5 minutes. After 120 cars, the equipment needs to be cleaned and maintained for 2 hours. What is the Effective Cycle Time per car-wash in minutes? 2 5 6 60 12011. Which is NOT a cause for Downtime? Machine maintenance Material shortage Workload leveling Setup or changeover Equipment adjustment System breakdown12. Which is NOT a Poka-Yoke device? Fuse Password Auto-stop Notepad Key13. Gary breaks down customer demands into small production orders. He sequences the work to ensure all operators are loaded and all customers can be served within one month. How is this process called? Heijunka Pitch Takt Kaikaku Gemba14. To create Lean Process through Lean Thinking, what is the right sequence? (A) allow pull, (B) specify value, (C) define process, (D) create flow, (E) eliminate waste. BCDEA ABCDE CDEBA CBDEA BCEDA15. What is the characteristic of a Lean Process Step? Valuable Capable Available Flexible All above16. A coffee machine was excessively used without a break. Then it burned out. Which type of loss is this? Maki Mura Mao Muda Muri17. Because workload varies from day-to-day, Harry needs to hire one extra person. What type of loss is this? Muri Maki Muda Mura Mao18. Klaus walks to the printing room to pick up a document. How is this activity classified? Mao Mura Muda Muri Maki19. Which work is considered Incidental Work or Muda-1 (type one)? Waiting for approval Making a mistake Poorly managing people Washing hands before preparing food Walking around to find required parts20. Which activity is adding Value? Customer is a guest who ordered a meal. Purchasing groceries Cooking spaghetti Bringing meal to table Washing the dishes Taking the order21. Dennis checks the document archive. The archive is well organized and standardized, but not all documents are filed correctly. Which is the level of 5S? 1 2 3 4 522. A trainee was only half of the time at his desk (available for work), took two times longer than expected to complete the job, and 80% of his work was correct. How efficient is the trainee? Calculate OPE, same formula as OEE. 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%23. Which is correct about Jidoka? Enables continuous improvement Detects abnormal conditions Eliminates overproduction waste Balances the workload Prevents human mistakes24. Mark sells 200 cups per year that he purchased at $1 each. In average, he keeps $100 worth of inventory. How often does his inventory turn? 1 2 3 4 5 10 50 10025. Wayne analyzes quality defects. He identified root-causes and improved the process. As a result, quality level increased from 97% to 99%. How is this method called? Gemba Poka-Yoke Kaizen Kaikaku Heijunka26. Paolo makes 100 pizzas per 10-hour day. During the peak-hour, he makes 30 pizzas. What is the Takt Time during the peak hour? 1 minute 2 minutes 30 minutes 60 minutes 3 pizzas 10 pizzas 30 pizzas 33 pizzas 100 pizzas27. Cabinet-A is perfectly organized. Cabinet-B is clean and shiny. The remaining office is just sorted. What is the overall 5S level? Consider those three elements. 1 2 3 4 528. Which element is NOT part of 5S-Standardizing? Item label Outline marking Shadow marking Cleaning instruction Reference photo29. Kevin keeps extra beer at home, just in case his friends visit to watch a game. What type of inventory is this? Raw material Finished goods Work in process Buffer stock Safety stock30. Which is NOT essential for a Just-in-Time system? Takt time Pull system Load leveling Continuous flow Error proofing31. Sandy prepares a presentation that her boss requested. To make a good impression, she reformats the document several times. But her boss only needs data to make a decision. Is there any waste? No, because a presentation should be perfect No, because Sandy wants to make a good impression No, because reformatting allows catching mistakes Yes, because of excessive processing Yes, because a presentation is not required32. The Simson family consumes 5 eggs per day. When going shopping, they buy two boxes with 10 eggs each, 20 total. What is the shopping Pitch? 5 eggs 10 eggs 20 eggs 2 days 4 days 10 days33. What is the goal of TPM? Eliminate uneven workload Eliminate unscheduled downtime Eliminate incorrect processing Eliminate overproduction waste Eliminate machine changeovers34. Bruce buys spare parts, just in case the equipment breaks and the supplier cannot deliver quickly enough. What type of inventory is this? Raw material Finished goods Work in process Buffer stock Safety stock35. At Brazilian barbecue restaurants, guests use red-green tokens to signal the waiter to bring more meat (green) or to stop (red). How is this device called? Poka-Yoke Kanban Andon Stopper Trigger36. What does a Spaghetti Chart show? Path an item travels through the value stream Utility wiring diagram (electric, water, gas) Relationship between an item and its product family Structure of a work station or work cell Connection between leader and team members37. Which information is NOT part of Standard Work? Takt or rate Work sequence Process steps Work schedule Process name38. Which statement is NOT related to Push? Mass-production approach Moving items when next process is ready Causes overproduction Increases inventory Reduces work balance39. What is the PDCA cycle used for? Problem solving Performance management Waste reduction Continuous improvement All of the above40. Anna works as a cook in a restaurant. After completing the breakfast service, she is washing pots and plates. After 8 minutes cleaning, the kitchen is ready to cook lunch. What is this process called? Gemba Kaizen SMED Pull Push41. The postal service performs at Six Sigma quality level. Out of 1 million parcels, how many are delivered incorrectly? 1.2 defects or 99.99988% correct 3.4 defects or 99.99966% correct 233 defects or 99.977% correct 6,210 defects or 99.38% correct 66,807 defects or 93.3% correct 308,538 defects or 69.1% correct42. Which is NOT part of the Six Losses, specified in TPM? Breakdowns Changeover Measurement Speed losses Rework and scrap43. Which activity is considered Waste? Waiting for an approval from your boss Correcting a mistake after checking the work Producing more just in case the customer wants more Readjusting a machine to make sure it works properly Keeping high quality standard by removing bad parts All of the above44. How to calculate Pitch? Consider the time required to complete one package. Takt-time x batch-quantity Takt-time / batch-quantity Takt time x pack-out quantity Takt time / pack-out quantity Cycle-time x pack-out quantity Cycle-time / pack-out quantity Cycle-time x batch quantity Cycle-time / batch quantity45. Fred goes to McDonalds for lunch. It takes 10 minutes to get his meal: 7 minutes to stand in line, 1 minute to order and pay, and 2 minutes to prepare the meal. What is the value-adding percentage? 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%46. Which is NOT related to Overproduction? Producing more than required by the next process Producing sooner than required by the next process Producing faster than required by the next process Producing better quality than required by the next process Producing with fewer steps than specified per standard47. Which is NOT a cause for Planned Downtime? Changeover Preparation Cleanup Adjustment Maintenance48. How to calculate Takt Time? Customer demand in units / Available time Customer demand in units x Available time Available time x Customer demand in units Available time / Customer demand in units None of the above answer is correct49. What means Overprocessing? Producing more than required by the next process Producing sooner than required by the next process Producing faster than required by the next process Producing better quality than required by the next process Producing with fewer steps than specified per standard50. Which statement is correct about the Five Whys? Define a corrective action Measure workplace organization Identify the root cause Create a problem statement Analyze five different problemsEnter your full name to confirm that you respected and will respect the Fair-Play rules, not not share any information about the exam. Click "Send" to submit your exam for grading. Questions must be answered in one session. If you lose Internet connection or need a break, do not close your browser; just resume when you are ready.Please wait while we process your inputs and calculate the result.