EXAMPLE LEVEL 1A MCT QUESTIONS & ALIGNMENT TO LCS FRAMEWORK 1A LEVEL DESCRIPTOR (LEAN AWARENESS KNOWLEDGE) Origins and evolution of lean thinking (eg Toyota, Ford, Deming, TWI, etc). Underpinning and related concepts (eg PDCA, scientific method, continuous improvement, systems thinking, etc) Key lean principles (eg Womack & Jones, Spear & Bowen etc); value, value stream, flow, pull, perfection Wastes (identification, categorisation etc); value adding, necessary non-value adding and non-value adding activities; value demand/failure demand 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. 1 Lean thinking s fifth principle (Womack & Jones) is concerned with which of the following? 2 What are the seven wastes of the Toyota Production System? (to be listed) a) The quality or condition of being perfect 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 a) Transport b) Inventory c) Motion Page 1 of 8
3 marks if all correct 2 if six correct 1 if five correct 3 A value stream shows all activities from order to what? 4 What is the correct order of Womack & Jones lean principles? Place a number between 1 5 against each principle d) Waiting e) Overproduction f) Over processing g) Defects a) Consumption b) Production c) Delivery d) Customer service e) Storage a) Pursue Perfection (5) b) Create Flow (3) c) Identify the Value Stream (2) d) Specify Customer Value (1) e) Create Pull (4) 5 PDCA is a systematic problem solving process. Match the letter with the action. 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? 7 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) Measure improvement. (C) b) Implement as standard.(a) c) Identify root cause. (P) d) Trial solution. (D) a) Important in delivering value to customers. b) Part of the operation s support function. c) Required by current state but Is difficult to remove today. d) Ready for immediate removal. a) Sorted b) Specified c) Standardised d) Synchronised,, 8 A successful lean implementation should a) Reduce headcount, Page 2 of 8
primarily achieve which one of the following? b) Improve profitability c) Release capacity d) Increase stock value 9 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 g) Overburden h) Unevenness i) Overstocking 10 A contingent approach to lean thinking implies what? 11 Womack has an abbreviated definition of lean, which is Lean = purpose + process + what? a) You adopt a prescriptive approach to lean implementation 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 a) Planet b) Policy c) People d) Practice 12 Policy deployment primarily aims to achieve which of the following? 13 Complete this quote by Henry Ford: every process should be regarded as what. 14 According to Spear & Bowen, any improvement must be made in accordance with what, under the guidance of a a) The control of workers actions and performance b) Ensuring business targets are met c) of actions with strategic objectives d) To formulate an effective strategy. a) Standardised b) Innovative c) Experimental d) Experiential a) Scientific management b) Simplified communications c) Standard operations Page 3 of 8
teacher, at the lowest possible level in the organization? d) Scientific method 15 What is Takt time? a) The time it takes to make a standard product 16 Policy deployment primarily aims to achieve which of the following? 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 a) The control of workers actions and performance b) Ensuring business targets are met c) of actions with strategic objectives d) To formulate an effective strategy. 17 The Pareto principle is often referred to as what? 18 Complete the quote by W Edwards Deming: In God we trust. All others must bring xxxx 19 In lean thinking terms perfection is which one of the following a) The 80:20 rule b) The 95:5 rule c) The law of the vital many d) The principle of factor disparity a) Solutions b) Plans c) Data d) Methods a) The endless pursuit to be perfect. 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? 21 The opposite of Single Piece Flow is a) Consumption b) Production c) Delivery d) Customer service e) Storage a) A chaotic system Page 4 of 8
22 Which is considered the worst of Taiichi Ohno s seven wastes? 23 From whose perspective should value be identified in a lean organisation? 24 Who in a company should own standard processes? 25 In a service environment, pull should be based on what? 26 To where should the lean practitioner go in order to learn and discover the facts about work? 27 In Spear & Bowen s four rules of the Toyota DNA, any improvement must be made in accordance with what? 28 In a lean process, you should only do what the customer will... b) Multiple piece flow c) Batch and queue production d) Shared services a) Transport b) Inventory c) Motion d) Waiting e) Overproduction f) Over processing g) Defects a) Stakeholders b) Customers c) Suppliers d) Shareholders a) Management b) Engineering c) Front line employees d) Quality control a) TAKT time b) Kanban c) Real customer demand d) Service delivery capacity j) The warehouse k) The gemba l) The gamba m) The supply chain a) Standardised processes b) Reference to customer value c) The scientific method d) Company strategy a) Want to stock b) Want to take delivery of c) Want to pay for Page 5 of 8
d) Want to consume 29 Emiliani has stated that real lean is a combination of continuous improvement plus what? 30 The amount of time taken to complete an operation is called what? 31 Which industrialist is said to have inspired the creation of the Toyota Production System? 32 What is the acronym used to remember the classic seven wastes? 33 In services, what is the term used to describe the demand that arises due to a previous fault in operations or service? 34 Womack has an abbreviated definition of lean, which is lean = purpose + process + what? 35 What term describes the techniques developed in World War II to improve aircraft production that are said to form the foundation of lean thinking? 36 Which of these is not one of Bicheno s new service wastes? a) Focus on the customer b) Respect for people c) Respect for the process d) Effective problem solving a) Cycle time b) Takt time c) Lead time d) Just in time a) Jack Welch b) W Edwards Deming c) Henry Ford d) Karl Benz a) TOD WOLD b) TED WARD c) TIM WOOD d) TOM WENT a) Non added value demand b) Failure demand c) Customer complaints demand d) System breakdown demand a) Planet b) Policy c) People d) Practice e) Patience a) Total Quality Management b) Training Within Industry c) Toyota Production System d) Industrial Engineering a) Waste of inappropriate systems b) Waste of lack of concentration c) Waste of untapped human potential, Page 6 of 8
d) Waste of excessive information & communication 37 Functionalising processes will most likely result in what? 38 The biggest impact on improved flow can be achieved through which one of the following? 39 TAKT time is which one of the following? 40 In which book was the word lean first used? 41 Which two of the following does value stream mapping aim to depict? 42 Which one of the following phrases best summarises the approach underpinning standardisation? 43 Which World War Two operations and training system is said to have inspired Toyota? a) Reduced lead times b) Improved quality c) Batching of work d) Improved efficiencies a) The use of larger batches b) The reduction in the space used in the process c) A reduction in inventory held d) The use of smaller batches a) The rate that stock is replenished b) The time it takes to complete one cycle c) The speed that the customer pulls d) The rate at which an operator works a) The Machine that Changed the World b) Lean Thinking c) Lean Solutions d) The Toyota Way a) People flow b) Material flow c) Information flow d) Stock flow a) Keeping organised b) A place for everything, everything in its place c) One best way d) Control through discipline a) Business Process Reengineering b) Total Quality Management c) Six Sigma 44 What does PDCA stand for? a) Plan d) Training Within Industry b) Do c) Check d) Act Page 7 of 8
LEARNING OUTCOMES COVERAGE CHECK Number of questions addressing each area 6 8 23 6 5 Page 8 of 8