Total Quality Management Questions and Answers – Lean Manufacturing Tools – Heijunka, Hoshin Kanri, Takt Time, Continuous Flow and Bottleneck Analysis

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This set of Total Quality Management Objective Questions & Answers focuses on “Lean Manufacturing Tools – Heijunka, Hoshin Kanri, Takt Time, Continuous Flow and Bottleneck Analysis”.

1. Which of the following refers to ‘Level Scheduling’?
a) Andon
b) Muda
c) Heijunka
d) Muri
View Answer

Answer: c
Explanation: Heijunka is a Japanese word that refers to ‘Level Scheduling’. It reduces lead time and inventory.

2. Which of the following is not a benefit of Heijunka?
a) Predictability
b) Flexibility
c) Stability
d) Uncertainty
View Answer

Answer: d
Explanation: Predictability, Flexibility, and Stability are the benefits of Heijunka. It helps in avoiding inefficiencies in manufacturing by putting production close to customer demand.

3. Calculate Takt Time when there are 500 minutes in work day and the customer demand is 500 units a day.
a) 1 minute
b) 2 minutes
c) 3 minutes
d) 4 minutes
View Answer

Answer: a
Explanation: Takt Time = Net available work time / Customer demand, or, Takt time=500/500=1 minute. Takt Time is an important parameter measured in lean manufacturing.
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4. Which of the following is the meaning of the word HoshinKanri which is extensively used in strategic planning?
a) Visual communication
b) Policy deployment
c) Audio communication
d) Benchmarking
View Answer

Answer: b
Explanation: HoshinKanri refers to policy deployment. It is utilized for ensuring that the strategic goals of the company is driven by progress and action at every level within the company.

5. HoshinKanri eliminates wastes that originate from poor communication and inconsistent direction.
a) True
b) False
View Answer

Answer: a
Explanation: HoshinKanri eliminates wastes that originate from poor communication and inconsistent direction. It is a progress and action driven strategic planning method.

6. The implementation of HoshinKanri begins with a strategic plan.
a) True
b) False
View Answer

Answer: a
Explanation: The implementation of HoshinKanri begins with a strategic plan. It is developed by top management. The plan should focus on effectiveness. It can be evolutionary or revolutionary.

7. In HoshinKanri, the tactics are laid out by ________
a) Top management
b) Middle management
c) Supervisors
d) Team Leaders
View Answer

Answer: b
Explanation: In HoshinKanri, the tactics are laid out by middle management. Supervisors and team leaders at the plant floor level work out the operational details needed in implementing tactics.
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8. Which of the following wastes is not eliminated by implementation of continuous flow?
a) Inventory
b) Waiting time
c) Transport
d) Quality
View Answer

Answer: d
Explanation: The implementation of continuous flow leads to elimination of wastes like inventory, waiting time, and transport. Quality is a desired characteristic.

9. Continuous flow is a technique of manufacturing where work-in-process smoothly flows through production with ______ buffers between various steps of the manufacturing process.
a) Minimal or no
b) Maximum
c) Sometimes minimal
d) Cannot be determined
View Answer

Answer: a
Explanation: Continuous flow is a technique of manufacturing where work-in-process smoothly flows through production with minimal or no buffers between various steps of the manufacturing process. It eliminates wastes like inventory, waiting time, and transport.
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10. Bottleneck analysis ______
a) Reduces throughput
b) Decreases throughput
c) Improves throughput
d) Cannot be determined
View Answer

Answer: c
Explanation: Bottleneck analysis improves throughput. It does so by strengthening the weakest link in the manufacturing process.

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Manish Bhojasia, a technology veteran with 20+ years @ Cisco & Wipro, is Founder and CTO at Sanfoundry. He lives in Bangalore, and focuses on development of Linux Kernel, SAN Technologies, Advanced C, Data Structures & Alogrithms. Stay connected with him at LinkedIn.

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