ME 503 MIDTERM QUESTIONS AND VERIFIED
ANSWERS
The most important contribution by Henry Ford that helped increase productivity and
reduce cost of production was: - Answers - The moving assembly line
Which of the following best describes 'true lean'? - Answers - It is about people who do
the work improving their own work continuously, with support and training from
management
Which of the following formed the foundation of the Toyota House? - Answers - Toyota
Way Philosophy
The two pillars in the Toyota Way Philosophy are: - Answers - Respect for people and
continuous improvement
In the Toyota Production System, emphasis is placed not only on the results of a
particular task but also on the method/procedure of doing this task. Briefly explain the
reason for doing this: - Answers - A strong importance is placed on the
methods/procedure of doing a tasks because teams at Toyota want to ensure that they
are able to repeat procedures to solve future problems that may arise. If there is no
method/procedure, the solution would just be considered mere luck because it could not
be reproduced. There must be a standardized and documented way of reaching
solutions in order to adhere to true lean standards.
'A company can be successful in its lean transformation if all the tools are implemented'.
Briefly explain whether you agree or disagree with this statement and why - Answers - I
disagree with this statement because lean tools do not equate to lean thinking. The
statement above is a misconception that many companies have because they think they
can implement lean principles with only adopting tools such as 5S, but true lean is an
evolutionary change that requires a shift in culture. There must be great support,
understanding and educational programs from upper management and leadership to
share the importance of constant dedication to lean principles with every member of
their team in the company. Culture is often the most difficult to change, but is vital to the
lean transformation
Idling machines are not considered a waste. - Answers - True
Utilization-driven manufacturing will eliminate some types of waste. - Answers - False
Harnessing the creativity and skills of employees is time consuming and wasteful. -
Answers - False
Searching for tools necessary to change the die is a waste. - Answers - True
, Excess inventory in a system is a symptom of overproduction. - Answers - True
According to specifications, a part needs to be machined to a certain diameter. Because
the grinding machine is available, the operator decides to polish the machined
component to improve its surface quality. This is a waste. - Answers - True
Having excess inventory between work stations will help reduce lead time. - Answers -
False
To reduce cost, products must be manufactured ahead of when needed and held in
inventory. - Answers - False
Lean Manufacturing is a system for total waste elimination. - Answers - True
Transportation, more than the minimum necessary to complete the value added
activities, is a waste. - Answers - True
A value stream map is developed for: - Answers - For a family of products
Which of the following statements is correct about a value stream map? - Answers - It
shows material and information flows in a production line
A value stream map should be developed by walking the line, starting from: - Answers -
The process closest to the customer or end of the production line
In a value stream map, information flow is shown from right to left at the bottom and
material flow is shown from left to right at the top. - Answers - False (opposite)
Which of the following is not an advisable practice when developing value stream
maps? - Answers - Value stream maps must be created for every purchased part in a
product/product family.
Implementing 5S helps eliminate waste due to searching, transporting, and
obsolescence . - Answers - True
Effective workplace layout and workstation ergonomics should be considered when
implementing 5S. - Answers - True
The red tagging strategy is a method used during day-to-day housekeeping for 5S. -
Answers - False (happens periodically, but not daily)
5S is not a prerequisite for implementing lean manufacturing. - Answers - False
The first and second 'S's in the 5S, respectively, involve: - Answers - Sorting and
Organizing
ANSWERS
The most important contribution by Henry Ford that helped increase productivity and
reduce cost of production was: - Answers - The moving assembly line
Which of the following best describes 'true lean'? - Answers - It is about people who do
the work improving their own work continuously, with support and training from
management
Which of the following formed the foundation of the Toyota House? - Answers - Toyota
Way Philosophy
The two pillars in the Toyota Way Philosophy are: - Answers - Respect for people and
continuous improvement
In the Toyota Production System, emphasis is placed not only on the results of a
particular task but also on the method/procedure of doing this task. Briefly explain the
reason for doing this: - Answers - A strong importance is placed on the
methods/procedure of doing a tasks because teams at Toyota want to ensure that they
are able to repeat procedures to solve future problems that may arise. If there is no
method/procedure, the solution would just be considered mere luck because it could not
be reproduced. There must be a standardized and documented way of reaching
solutions in order to adhere to true lean standards.
'A company can be successful in its lean transformation if all the tools are implemented'.
Briefly explain whether you agree or disagree with this statement and why - Answers - I
disagree with this statement because lean tools do not equate to lean thinking. The
statement above is a misconception that many companies have because they think they
can implement lean principles with only adopting tools such as 5S, but true lean is an
evolutionary change that requires a shift in culture. There must be great support,
understanding and educational programs from upper management and leadership to
share the importance of constant dedication to lean principles with every member of
their team in the company. Culture is often the most difficult to change, but is vital to the
lean transformation
Idling machines are not considered a waste. - Answers - True
Utilization-driven manufacturing will eliminate some types of waste. - Answers - False
Harnessing the creativity and skills of employees is time consuming and wasteful. -
Answers - False
Searching for tools necessary to change the die is a waste. - Answers - True
, Excess inventory in a system is a symptom of overproduction. - Answers - True
According to specifications, a part needs to be machined to a certain diameter. Because
the grinding machine is available, the operator decides to polish the machined
component to improve its surface quality. This is a waste. - Answers - True
Having excess inventory between work stations will help reduce lead time. - Answers -
False
To reduce cost, products must be manufactured ahead of when needed and held in
inventory. - Answers - False
Lean Manufacturing is a system for total waste elimination. - Answers - True
Transportation, more than the minimum necessary to complete the value added
activities, is a waste. - Answers - True
A value stream map is developed for: - Answers - For a family of products
Which of the following statements is correct about a value stream map? - Answers - It
shows material and information flows in a production line
A value stream map should be developed by walking the line, starting from: - Answers -
The process closest to the customer or end of the production line
In a value stream map, information flow is shown from right to left at the bottom and
material flow is shown from left to right at the top. - Answers - False (opposite)
Which of the following is not an advisable practice when developing value stream
maps? - Answers - Value stream maps must be created for every purchased part in a
product/product family.
Implementing 5S helps eliminate waste due to searching, transporting, and
obsolescence . - Answers - True
Effective workplace layout and workstation ergonomics should be considered when
implementing 5S. - Answers - True
The red tagging strategy is a method used during day-to-day housekeeping for 5S. -
Answers - False (happens periodically, but not daily)
5S is not a prerequisite for implementing lean manufacturing. - Answers - False
The first and second 'S's in the 5S, respectively, involve: - Answers - Sorting and
Organizing
