Total Quality Management Questions and Answers – Lean Manufacturing Tools – Seven Types of Wastes, Andon and Gemba

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This set of Total Quality Management online quiz focuses on “Lean Manufacturing Tools – Seven Types of Wastes, Andon and Gemba”.

1. Who is the father of Toyota Production System (TPS)?
a) Ohno
b) Deming
c) Crosby
d) Taguchi
View Answer

Answer: a
Explanation: The father of Toyota Production System is Ohno. The concept of Toyota Production System is popularly known as Lean Manufacturing in North America.

2. ‘Muda’ refers to waste in Japan.
a) True
b) False
View Answer

Answer: a
Explanation: ‘Muda’ refers to waste in Japan. The seven types of wastes were categorized by Taiichi Ohno.

3. Mura and Muri refer to _____ and _____ respectively.
a) Unevenness, waste
b) Unevenness, overburden
c) Overburden, waste
d) Overburden, poka-yoke
View Answer

Answer: b
Explanation: Mura and Muri refer to unevenness and overburden respectively. The concept of Lean has been developed around eliminating the three types of deviations showing inefficient allocation of resources.
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4. Muda Type 1 refers to non-value-added activities in the processes that are important for the end customer.
a) True
b) False
View Answer

Answer: a
Explanation: Muda Type 1 refers to non-value-added activities in the processes that are important for the end customer. Muda Type 2 refers to non-value-added activities in the processes that are unnecessary for the end customer.

5. Inspection and safety testing are examples of Muda ____
a) Type 4
b) Type 3
c) Type 2
d) Type 1
View Answer

Answer: d
Explanation: Inspection and safety testing are examples of Muda Type 1. They do not add any value to the final product but are necessary for the end customer.
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6. Which of the following terms in the seven types of wastes categorized by Ohno considers the movement of product between manufacturing processes as no value-addition task, expensive and can cause damage to the product?
a) Overproduction
b) Waiting
c) Transportation
d) Excessive inventory
View Answer

Answer: c
Explanation: ‘Transportation’ refers to the movement of product between manufacturing processes as no value-addition task, expensive and can cause damage to the product. It should be avoided as much as possible.

7. Which of the following terms in the seven types of wastes categorized by Ohno considers the waiting of one process to begin while the other one gets over?
a) Overproduction
b) Waiting
c) Transportation
d) Excessive inventory
View Answer

Answer: b
Explanation: ‘Waiting’ refers to the waiting of one process to begin while the other one gets over. Operations flow must be smooth and continuous.
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8. Which of the following does not belong to the seven types of wastes categorized by Ohno?
a) Inappropriate processing
b) Excess inventory
c) Unnecessary motion
d) Quality
View Answer

Answer: d
Explanation: Inappropriate processing, excess inventory, and unnecessary motion belong to the seven types of wastes categorized by Ohno. Defects also belong to the seven types of wastes categorized by Ohno.

9. Which of the following is a visual and/or audible communication system that calls for support or attention in a process whenever needed?
a) Poka-yoke
b) Benchmarking
c) Andon
d) Muda
View Answer

Answer: c
Explanation: Andon is a visual and/or audible communication system that calls for support or attention in a process whenever needed. It could be a cord, light, or a flag.
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10. Which philosophy tells us that we need to go out of the office and visit the plant floor where the real action occurs?
a) Benchmarking
b) FMEA
c) Gemba
d) Andon
View Answer

Answer: c
Explanation: The Gemba is the philosophy that tells us we need to go out of the office and visit the plant floor where the real action occurs. It helps in getting first-hand observation and by talking with employees on the plant floor.

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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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