Lean Michelin
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Questions and Answers

Which one of the following is considered value-added work?

  • Reworking parts
  • Entering data into computer system for regulatory reports (correct)
  • Collecting payments from customers
  • Inspecting products for defects

    • Which one of the following is a major category of waste?

  • Assisting customers in finding the right financial product
  • Assembling the product
  • Overextension of capacities (correct)
  • Building quality into all steps of the process

    • Lean focuses on the elimination of waste, variation, and work imbalance. What must each step in Lean create for the customer?

  • Efficiency
  • Value (correct)
  • Profit
  • Capacity

    • Which one of the following is a driver of waste?

    <p>Running or operating at an uneven pace</p> Signup and view all the answers

    What is the Lean objective?

    <p>To produce and deliver the highest quality products and services at the lowest possible cost</p> Signup and view all the answers

    What are the two key drivers of waste in organizations?

    <p>Running or operating at an uneven pace and eliminating waste in the system</p> Signup and view all the answers

    Which of the following is a key goal of Lean philosophy?

    <p>Providing customers with exactly what they want</p> Signup and view all the answers

    What is the definition of a standard in Lean philosophy?

    <p>The best way to do something known and shared by everyone at a given time</p> Signup and view all the answers

    What are the three views in Lean Production Standards?

    <p>Product view, Process view, Operation view</p> Signup and view all the answers

    What is the purpose of Takt Time in Lean philosophy?

    <p>To synchronize production with customer demand</p> Signup and view all the answers

    What are the 5 phases of Modern Six Sigma?

    <p>Define, Measure, Analyze, Improve, Control</p> Signup and view all the answers

    What percentage of information does a human collect through sight, according to the text?

    <p>83%</p> Signup and view all the answers

    What is the purpose of Visual Management, according to the text?

    <p>To show and control the process</p> Signup and view all the answers

    What is the purpose of the DMAIC method, according to the text?

    <p>To identify the root causes</p> Signup and view all the answers

    What criteria should be considered when selecting Lean Six Sigma projects?

    <p>Business issues and objectives addressed</p> Signup and view all the answers

    Which of the following is a key step in the SIPOC methodology?

    <p>Identifying necessary inputs and suppliers</p> Signup and view all the answers

    What must be done before identifying necessary inputs and suppliers in the SIPOC methodology?

    <p>Identify process outputs</p> Signup and view all the answers

    Which of the following criteria should be considered first when selecting Lean Six Sigma projects?

    <p>Projects that are linked to a key business issue or objective</p> Signup and view all the answers

    What is the purpose of selecting well-defined improvement projects?

    <p>To ensure better, faster results</p> Signup and view all the answers

    What is the key objective of Lean philosophy?

    <p>To eliminate waste, variation, and work imbalance</p> Signup and view all the answers

    What is the purpose of Visual Management?

    <p>To provide visual indicators of performance</p> Signup and view all the answers

    Which methodology is used to arrive at a data-driven solution in Lean Six Sigma?

    <p>DMAIC</p> Signup and view all the answers

    What is the purpose of the Define phase in the DMAIC methodology?

    <p>To define project objectives and attain the Voice of the Customer</p> Signup and view all the answers

    What is the purpose of the Measure phase in the DMAIC methodology?

    <p>To measure and collect data on process performance</p> Signup and view all the answers

    What is the purpose of the Analyze phase in the DMAIC methodology?

    <p>To analyze data and identify root causes</p> Signup and view all the answers

    What is the purpose of the Improve phase in the DMAIC methodology?

    <p>To implement and verify improvements</p> Signup and view all the answers

    What is the purpose of the Voice of the Customer (VOC) in Lean Six Sigma?

    <p>All of the above</p> Signup and view all the answers

    Which of the following is an example of a reactive VOC system?

    <p>Customer complaints</p> Signup and view all the answers

    Which of the following is a guideline for surveying?

    <p>Keep the survey short and simple</p> Signup and view all the answers

    What are the needs, wants, expectations, and preferences of the people who constitute the business itself called?

    <p>Voice of Business (VOB)</p> Signup and view all the answers

    Which of the following is an example of the Voice of Team (VOT)?

    <p>Problems faced by team members with the current process</p> Signup and view all the answers

    Which one of the following is the purpose of the SIPOC methodology?

    <p>To create a high-level view of the process</p> Signup and view all the answers

    What is the formula for calculating process yield?

    <p>Process Yield = (Good Units / Total Units) x 100</p> Signup and view all the answers

    What is the formula for calculating Process DPMO (Nonconform Rate)?

    <p>Process DPMO = (Defective Units / Total Units) x 1,000,000</p> Signup and view all the answers

    What is the formula for calculating Rolled Throughput Yield?

    <p>RTY = Yield Step A x Yield Step B x Yield Step C</p> Signup and view all the answers

    What is the purpose of calculating Rolled Throughput Yield?

    <p>To establish a baseline for the entire process</p> Signup and view all the answers

    What is the formula for calculating Cycle Time using Little's Law?

    <p>Cycle Time = Work in Process / Exit Rate</p> Signup and view all the answers

    What is the formula for calculating TAKT Time?

    <p>TAKT Time = Total Daily Operating Time / Total Daily Requirement</p> Signup and view all the answers

    What is the purpose of Work Sequence in Standard Operations?

    <p>To define the sequence of activities performed by a worker</p> Signup and view all the answers

    What does OEE/TRS measure in equipment production process?

    <p>Availability of equipment, Performance efficiency, and Rate of quality products</p> Signup and view all the answers

    Which of the following is NOT a factor that contributes to downtime in production?

    <p>Actual operating time</p> Signup and view all the answers

    What is the formula for calculating OEE or TRS?

    <p>Availability * Performance efficiency * Rate of quality products</p> Signup and view all the answers

    What is the purpose of translating VOC (Voice of the Customer) into CTQs (Critical to Quality)?

    <p>To quantify customer needs and requirements</p> Signup and view all the answers

    Which of the following is a key deliverable of the Define Phase in the DMAIC methodology?

    <p>All of the above.</p> Signup and view all the answers

    What is the value stream?

    <p>The set of activities required to bring a product or service into the hands of the customer.</p> Signup and view all the answers

    What is the purpose of the Priority Matrix in Lean Six Sigma?

    <p>To prioritize which problems to tackle first.</p> Signup and view all the answers

    What is the formula for calculating % VA (Value-Added) using the Value Stream Mapping (VSM) methodology?

    <p>% VA = (VA time / Total cycle time) x 100%</p> Signup and view all the answers

    What is the key objective of Lean philosophy?

    <p>To eliminate waste.</p> Signup and view all the answers

    What is the purpose of the current state value stream map in Lean Six Sigma?

    <p>To determine what the process currently looks like</p> Signup and view all the answers

    Which technique is used to identify root causes by asking 'Why' multiple times?

    <p>The 5 Why Technique</p> Signup and view all the answers

    What is the purpose of the 5 Why Technique?

    <p>To identify the root causes of a problem</p> Signup and view all the answers

    What is the purpose of the Analyze phase in the DMAIC methodology?

    <p>To identify root causes</p> Signup and view all the answers

    What is the purpose of an Ishikawa Diagram?

    <p>To stimulate thinking during a brainstorm of potential causes</p> Signup and view all the answers

    What is a common mistake to avoid when using an Ishikawa Diagram?

    <p>Using the tool as an alternative form of outlining</p> Signup and view all the answers

    What does an Ishikawa Diagram graphically display?

    <p>Cause-and-effect relationships between potential causes</p> Signup and view all the answers

    What is the purpose of an Ishikawa Diagram in problem-solving?

    <p>To visualize the relationships between potential causes</p> Signup and view all the answers

    What is the purpose of the 5S+1 tool in Lean?

    <p>To improve safety and organization</p> Signup and view all the answers

    Which of the following is NOT one of the 5S+1 objectives?

    <p>To identify the root cause of a problem.</p> Signup and view all the answers

    What does the EL-CO-MO-RE acronym stand for in waste reduction?

    <p>Eliminate, Combine, Modify, Reduce</p> Signup and view all the answers

    What is the purpose of the S2 - Store or Set in Order step of the 5S process?

    <p>To make things easy to use and aligned with the process flow</p> Signup and view all the answers

    What is the formula for calculating Changeover time in Lean?

    <p>Set-up time + Adjust time</p> Signup and view all the answers

    Which step of the 5S process involves cleaning up machines, equipment, floors, and walls?

    <p>S3 - Shine or Clean-up</p> Signup and view all the answers

    Which of the following is NOT a principle of Quick Changeover, according to the text?

    <p>Streamline external</p> Signup and view all the answers

    What is the definition of INTERNAL in Quick Changeover, according to the text?

    <p>Elements done with the machine stopped</p> Signup and view all the answers

    What is the definition of EXTERNAL in Quick Changeover, according to the text?

    <p>Elements done while the machine is running</p> Signup and view all the answers

    What is the purpose of a Cause-and-Effect Diagram?

    <p>To identify and organize possible causes</p> Signup and view all the answers

    What is the main difference between an I-Shaped Cell and a U-Shaped Cell?

    <p>Flexibility of Movement</p> Signup and view all the answers

    What is the purpose of Source Inspection in error-proofing?

    <p>To prevent errors from becoming defects</p> Signup and view all the answers

    What is the distinction between defects and errors?

    <p>Defects are results, errors are causes</p> Signup and view all the answers

    What are the types of Error-Proofing Devices?

    <p>Prevent and Detect</p> Signup and view all the answers

    Which of the following is a characteristic of Kanban?

    <p>It is a small card that regulates 'Pull' in the production system</p> Signup and view all the answers

    What is the ultimate goal of Kanban?

    <p>To achieve Just In Time production</p> Signup and view all the answers

    What is the purpose of Supermarkets in a pull system?

    <p>To provide visual control for inventory</p> Signup and view all the answers

    What is the benefit of Kitting in assembly environments?

    <p>Increases productivity</p> Signup and view all the answers

    Which one of the following is an example of a Pull production system?

    <p>Supermarket (goods on shelves)</p> Signup and view all the answers

    Which one of the following is a necessary element for a Pull production system?

    <p>High process stability</p> Signup and view all the answers

    Which one of the following is a characteristic of a Push production system?

    <p>Orders are launched ahead of delivery date</p> Signup and view all the answers

    Which one of the following is a benefit of holding finished goods inventory?

    <p>Ready to ship all inventory of all products</p> Signup and view all the answers

    Which one of the following is a characteristic of a Pull production system?

    <p>Requires inventory and floor space for each part number</p> Signup and view all the answers

    What is the purpose of the Improve phase in the DMAIC methodology?

    <p>To implement solutions onto the root causes</p> Signup and view all the answers

    Which phase of the process improvement cycle involves monitoring targets and CTQs to ensure the implemented improvements have a positive result?

    <p>Control Phase</p> Signup and view all the answers

    What is the best way to answer the question 'Did My Process Improve' in the process improvement cycle?

    <p>Before and after comparisons</p> Signup and view all the answers

    Which technique is used on the workspace to detect abnormalities and immediately engage corrective actions?

    <p>Visual Management</p> Signup and view all the answers

    What needs to be done to reflect new procedures in the process improvement cycle?

    <p>Update standards</p> Signup and view all the answers

    What is the purpose of the Impact Analysis?

    <p>To evaluate the perception of change by affected populations</p> Signup and view all the answers

    Which of the following is a key factor for a successful Lean implementation?

    <p>Clear objectives and adapted competencies</p> Signup and view all the answers

    What do studies show about organizational changes?

    <p>70% of organizational changes fail to achieve their objective</p> Signup and view all the answers

    What are the top two reasons for the inability to innovate and unwillingness to change?

    <p>Resistance to change and fear of the unknown</p> Signup and view all the answers

    Why is it important to create a sense of urgency in change management?

    <p>To ensure adequate mobilization</p> Signup and view all the answers

    What is the purpose of building a guiding coalition in change management?

    <p>To gain involvement and commitment</p> Signup and view all the answers

    Which one of the following is NOT a purpose of the RACI matrix?

    <p>To inform the person that an action has been taken</p> Signup and view all the answers

    How should a training need be expressed?

    <p>By defining the need, context, business challenges, and expected changes</p> Signup and view all the answers

    Why is it important to communicate the vision?

    <p>To clarify how the future will be different from the past</p> Signup and view all the answers

    Study Notes

    Steps for Creating a Cause-and-Effect Diagram

    • Step 1: Review the focused problem - high number of "major errors" caught in the last editing stage
    • Step 2: Identify possible causes - reporters not reviewing grammar, copyeditors too busy, reporters unaware of correct grammar, etc.
    • Step 3: Sort possible causes into reasonable clusters - clusters include grammar errors, use of spellchecker, copyeditors busy with facts, etc.
    • Step 4: Choose a cluster and label a main bone - cluster labeled "Copyeditors busy tracking down facts"
    • Step 5: Develop and arrange bones for that cluster - additional items added to the cluster, such as poor typing skills and spellchecker not user-friendly
    • Steps 6-8: Complete diagram and select causes to verify - diagram includes causes like grammar errors, misspelled words, and lack of spellchecker use
    • Results of accuracy checks unclear, high number of wrong names, numbers, and facts are also mentioned.
    • Cause-and-effect diagram helps identify and organize possible causes, but verification is needed before taking action.
    • Group activity: Creating an Ishikawa diagram - instructions for creating a cause-and-effect diagram as a team
    • Short loop and analyze phase outcome - identification of root causes and key inputs for major wastes and problem areas.

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    Michelin Lean Six Sigma Green Belt Test

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