Question 1

Which design of experiments principle is used to remove systematic error?

Accepted Answer

A) Replication, in which the number of tests should equal the number of replications. 
B) Efficiency, which is the lowest possible variance from any estimator divided by the expected variance of the selected estimator. 
C) Balance, which is evenly distributing both the quantity and variety of work across available work time, avoiding overburden and underuse of resources. 
D) The power of a hypothesis test to measure of the probability of rejecting the null hypothesis when it is false.

Question 2

Which lean tool would a project team utilize to determine all possible failures in a design, product, or process?

Accepted Answer

A) Root cause analysis. 
B) Failure Modes and Effects Analysis (FME
A) . 
C) Design of Experiments (DO
E) . 
D) Relations diagram checklist.

Question 3

Which of these choices is an example of an external cost related to an improvement?

Accepted Answer

A) A shift leader realizes they are short 130 cases of product for their shift. 
B) A lot number of books has to be retested for ink alignment. 
C) Environmental costs for environmental cleanup or abatement. 
D) A robotic arm which lifts assembly line automobiles is out of service.

Question 4

In the development of a lean team and a project charter, which stakeholder determines the project's strategic objectives?

Accepted Answer

A) The product or service customer. 
B) The project sponsor. 
C) The organization's senior management. 
D) The project manager.

Question 5

Kaikaku is used for breakthrough continuous improvement. Kaizen focuses on incremental improvements and Kaikaku focuses on what?

Accepted Answer

A) Successive incremental improvement. 
B) Radical change, transformation, and revolution. 
C) Synergistic effects of continuous improvement. 
D) The human aspects of inspection.

Question 6

Which would be the best choice of picture, chart, or diagram to show if the improvements implemented in a project are improving from the baseline or benchmarks?

Accepted Answer

A) Scatter diagrams of data. 
B) Pie chart representation. 
C) Trend analyses. 
D) Pareto diagrams.

Question 7

Which of the following would NOT be an issue encountered when collecting data for a lean project?

Accepted Answer

A) No data is available. 
B) Data does not measure what was intended to be measured. 
C) Only a limited number of employees have access to the data. 
D) The data has never been collected in the past.

Question 8

Check sheets are one of the seven tools of quality which include the cause and effect diagram, check sheet, control chart, flowchart, histogram, Pareto chart, and scatter diagram. The checklist is a mistake-proofing aid. What is a check sheet used for?

Accepted Answer

A) Auditing process outputs. 
B) Capturing and categorizing observations. 
C) Carrying out multi-step procedures. 
D) Finishing of process outputs.

Question 9

PDCA encourages small tests within current processes. Which phase of PDCA is the baseline for the current process being developed?

Accepted Answer

A) The act step of PDCA. 
B) The check step of PDCA. 
C) The do step of PDCA. 
D) The plan step of PDCA.

Question 10

Pareto charts are graphical tools used for ranking causes from most significant to least significant. Which of the following is incorrect regarding when you would use a Pareto chart?

Accepted Answer

A) When the causes are already known by a team. 
B) When you want to focus on the most significant problems or issue. 
C) When focusing on the frequency of problems. 
D) When communicating with a team about process data.

Question 11

A storage designer has developed acrylic prototypes of a new product. They are developing corresponding data for the process capability index. What does the process capability index do?

Accepted Answer

A) Estimates the costs of production. 
B) Determines the process critical path. 
C) Shows if the process can meet the requirements of a customer. 
D) Determines the probability of errors.

Question 12

In one piece flow manufacturing products are manufactured one at a time and flow through the manufacturing and supply chain as a single unit fabricated as the customer ordered. All of the following are indicators one piece flow should be used EXCEPT:

Accepted Answer

A) Leftover product at beginning and end of a production run. 
B) High inventory turns. 
C) Large batches of defects and rework with the same or similar defect. 
D) Long delivery lead times.

Question 13

The characteristics for control chart monitoring which require monitoring are common causes and special causes. Which of the following is NOT a control chart for special characteristics?

Accepted Answer

A) An x-chart. 
B) An r-chart.. 
C) A bp-chart. 
D) A t-chart.

Question 14

When visually managing the flow of a process, what is the primary goal of a visual project board?

Accepted Answer

A) To provide the status and progress of a project. 
B) To show the team members and charter for a project. 
C) To show the project timeline. 
D) To show the return on investment for the project.

Question 15

Which of the listed elements is NOT included in the base elements of a project charter?

Accepted Answer

A) Analysis of the problem. 
B) The project deliverables. 
C) Communication and status reporting processes. 
D) Responsibilities of team members.

Question 16

In project management, there are four leadership styles in a team approach. Which leadership style aligns with the "supporting" approach?

Accepted Answer

A) Used for teams which are empowered and self-directing. 
B) Used for teams that require continual support in terms of competencies and experience. 
C) Used for teams on the verge of being self-directed. 
D) Used for teams which are new or on time-sensitive projects

Question 17

The 7 classic wastes in lean include which grouping of concepts below?

Accepted Answer

A) Overproduction, inventory, defects, over-processing, waiting, motion, and transportation. 
B) Overproduction, marketing, returned products, over-processing, waiting, motion, and lack of training. 
C) Just-in-time production, inventory, failure points, over-processing, waiting, motion, and transportation. 
D) Muda, inventory, Muri, over-processing, defects, waiting, and motion.

Question 18

Taiichi Ohno studied waste and its impact on quality. Under his teachings, there are how many forms of waste?

Accepted Answer

A) Six forms of waste. 
B) Seven forms of waste. 
C) Eight forms of waste. 
D) Five forms of waste.

Question 19

Sensible automation is a form of lean batching. How is an analysis of lean batching performed or what measures are used?

Accepted Answer

A) Reviewing material usage and frequency. 
B) Reviewing the total cost of production. 
C) Reviewing labor costs 
D) Reviewing lot size and batch development.

Question 20

The Analyze phase core activities include analyzing data, determining root causes, and determining correlations, such as calculating the mean, mode, median, and variance. Calculate the mean, median, and mode of 5, 7, 9, 4, 5, and 6.

Accepted Answer

A) Mean 4, Median 4, Mode 4. 
B) Mean 5, Median 5, Mode 5. 
C) Mean 5, Median 7, Mode 4.5. 
D) Mean 6, Median 5.5, Mode 5.

Exam 2: Continuous Improvement