CHAPTER -1 : KAIZEN -Let us do Small improvements. Q-1 “Kaizen“ is word from which language ? A. English B. American C. Japanese D. Kazakistan E. Korean F. Hindi Q-2 “Kaizen“ has been derived from which two words A. Small Improvement B. Ka + izen C. Kai + Zen D. Kaiz + en Q-3 What is meaning of “KAI” in Kaizen ? A. To modify, to change B. Make good, make better. C. Small Improvement D. Quality E. Quality Circle F. Operational Excellence Q-4 What is meaning of “Zen” in Kaizen ? A. To modify, or to change B. Think, make good, or make better. C. Small Improvement D. Quality E. Quality Circle F. Operational Q-5 What is meaning of “Kaizen” ? A. Make it easier by studying it, and making the improvement through elimination of waste. B. Improve Quality and Market Share C. Reduce Cost & Win Award D. Share problems to top management. Q-6 Kaizen is the practice of what type of improvement. A. Small and Continuous Improvement B. Improvement in Manufacturing Area Only C. Applicable for Japanese Company Only Q-7 What is ‘TRUE’ about “Kaizen”? A. Good processes bring good results B. Go see for yourself to grasp the current situation C. Speak with data, manage by facts D. All of the above 1 Q-8 Fill in the blanks- One of the most notable features of kaizen is that big results come from many _____________ changes accumulated over time. A. Frequent B. Small C. Large D. All Types of Change Q-9 What is ‘TRUE’ about “Kaizen”? A. Take action to contain and correct root causes of problems B. Work as a team C. Kaizen is everybody’s business D. All of the above Q-10 One of the main objectives of Kaizen is “making the improvement through elimination of _________? A. Improvements B. Waste C. Challenges D. Breakdown only Q-11 As per Production System if VA is Value Addition. What is NVA? A. Non - Value Addition B. Non - Variable Asset C. Now - Value Addition Q-12 Fill in the Blanks? This is a Japanese word that literally means "the Real Place". Used in the context of KAIZEN, _________ usually refers to the shop floor or to the place where the Core Process is going on. A. Kaizen B. Gemba C. Seiton D. Shitshuki Q-13 Fill in the Blanks? ________________ is a Japanese term meaning "change for the better". Applied to business organizations, it implies continuing improvement involving everyone that does not cost much. A. Kaizen B. Gemba C. Seiton D. Shitshuki 2 Q-14 Identify this very famous personality in the field of Kaizen? A. Masaki Imai B. Dr. Ishikawa C. Dr. W. E. Deming D. Dr Sameer Kumar Q-15 Who is author of this book? A. Dr. W. E. Deming B. Dr. Ishikawa C. Masaki Imai D. Dr Kumar Sameer Q-16 Fill the missing word in Red Block? A. Kaizen B. Waste C. Improvement D. Down Time 3 Q-17 Fill the missing word in Red Block? A. Kaizen B. Waste C. Improvement D. Down Time Q-18 Who is author of this book? A. Dr. W.E. Deming B. Dr. Ishikawa C. Dr. J.M. Juran D. Masaki Imai 4 CHAPTER 1 Answers 1. C. JAPANESE 2. C. KAI + ZEN 3. A . TO MODIFY 4. B. THINK,MAKE GOOD 5. A. MAKE IT EASIER 6. A . SMALL AND CONTINUOUS IMPROVEMENT 7. D. ALL OF THESE 8. B. SMALL 9. D. ALL OF THESE 10. B WASTE 11. A. NON VALUE ADDITION OR NON VALUE ADDED 12. B. GEMBA OR GENBA 13. A. KAIZEN 14. A. MASAKI IMAI 15. C. MASAKI IMAI 16. B. WASTE 17. B. WASTE 18. D. MASAKI IMAI 5 CHAPTER 2 : “Five S & IMPROVEMENT” Q1- During Sort, you and your coworkers focus on what? A. Ensuring 5S continues to function B. Establishing assigned cleaning duties C. Developing uniformity in facility visual communication D. Eliminating needless tools and equipment from the workplace Q-2 During Set in Order, you and your coworkers focus on what? A. Begin finding a storage place for all tools and equipment B. Initiate visual communication color standards C. Commence work area cleaning D. Start eliminating needless tools Q-3 During Shine, you and your coworkers focus on what? A. Start following scheduled work area cleanings B. Begin documenting visual communication needs C. Establish a red tag zones D. Initiate "shadow labeling" for tool storage Q-4 Choose the Right / Correct Option During Standardize, you and your coworkers focus on what? A. Initiate work area review for cleanliness issues B. Begin organizing workplace with visual communication C. Start itemizing unnecessary equipment and tools for removal D. Establish uniform schedules for all 5S steps 6 Q-5 During Sustain, you and your coworkers focus on what? A. Photographing work areas for the first time B. Begin documentation of work area task times C. Ensuring all previous steps become facility-wide standards D. Start researching more efficient locations for storage Q-6 5S visual communication (Kaizen Activity Sheet) provides what advantage? A. Kaizen Sheet Reduces Cost B. Encourage others to do improvement C. It makes a facility look clean and efficient D. Only B&C Q-7 Work and Waste We all know about 7 wastes, 6 has been listed here. Find the missing One? A. Overproduction B. Bad Quality C. Movement D. Process E. Inventory F. Idle Time Q-8 Identify and Name the 5S activity from the picture? A. SORTING B. SHINE C. STANDADRISE D. SUSTAIN 7 Q-9 Find the missing word in Red Block’s? A. STANDARDISE B. SIMPLIFICATION C. GEMBA D. SIX SIGMA Q-10 Identify and Name the 5S activity from the picture? A. SET IN ORDER B. SHINE C. SORTING D.SUSTAIN Q-11 Identify and Name the 5S activity from the picture? A. STANDARDISE B.SET IN ORDER C.SHINE D.SUSTAIN 8 Q-12 Identify and Name the 5S activity from the picture? A. SET IN ORDER B. SHINE C. STANDARDISE Q-13 Identify and Name the 5S activity from the picture? A. SHINE B. SORTING C. SUSTAIN D. STANDARDISE Q-14 Identify and Name the 5S activity from the picture? A. SHINE B. SORTING C. SET IN ORDER D.SUSTAIN 9 Q-15 Work and Waste Which type of waste has been shown in the picture? A. Waiting B. Motion C. Over Procurement/Over Production D. Defect Q-16 Work and Waste Which type of waste has been shown in the picture? A. Waiting B. Motion C. Over Procurement D. Defect Q17- Work and Waste Which type of waste has been shown in the picture? A. Waiting B. Motion C. Over Procurement D. Defect 10 Q-18 Work and Waste Which type of waste is known as “Mother of all Waste”? A. Inventory B. Over Production C. Waiting D. Motion Q-19 This is a very famous book based on “Kaizen”. What is title of the Book? A. Masaki Imai B. KAIZEN C. Fish Bone D. Taguchi 11 Q-20 This is a very famous book based on 5S and authored by Hiroyuki Hirano. What is title of the Book? Q-21 This is a very famous book based on Procedures. What is title of the Book? ______ ________ is an agreed upon set of work procedures that effectively combines people, materials, and machines to maintain quality, efficiency, safety, and predictability. ____ _______ is described precisely in terms of cycle time, work in process, sequence, time, layout, and the inventory needed to conduct the activity. It establishes the best activities and sequence steps to maximize performance and minimize waste. A. Standard B. Kaizen C. Five (5) S D. Gemba Q-22 This is a “Japanese” word means “Mistake Proofing” in English. The aim of ____ ______ is to eliminate defects in a product by preventing or correcting mistakes as early as possible. What is this word? A. Kaizen B. Poka Yoke C. 5S D. T.P.M. 12 Q-23 What has been shown in these pictures? . A. Kaizen B. 5 S C. Poka Yoke D. T.P.M. Q-24 Find out the missing word in Red Block? A. KAIZEN B. 5S C. GEMBA D.SIX SIGMA Q-25 Find out the missing word in Red Block? ____Kaizen: Transforming __ Operations into a Strategic Competitive Advantage. O E 13 Q-26 This is a very famous book based on “Kaizen”. What is title of the Book? Q-27 What is special about #IM WOOD? Find out the missing word in #? Hint- #IM WOOD has Seven Letter. A. “T” AS TRANSPORT IN TIMWOOD 7 WASTES B. TIME MANAGEMENT C. THROTTLING Q-28 Find out the missing word in Red Block? A. KAIZEN B. MOTION C. DELAY D. DEFECT 14 CHAPTER 2 Answers 1. D. Eliminating needless tools and equipments. 2. A. Begin Finding 3. A. Start Following 4. D. Establish 5. C. Ensure All 6. D. Only B & C 7. D. Waiting Time 8. D. Sustain 9. A. Standardise 10. C. Sorting 11. B. Set in Order 12. A. Set in Order 13. A. Shine 14. D. Sustain 15. C. Over Production/Over Procurement 16. A. Waiting 17. B. Motion 18. B. Over Production 19. B Kaizen 20. A. 5S (FIVE S) FOR OPERATORS 21. A. STANDARDISATION 22. B. Poka Yoke 23. C. Poka Yoke 24. C. Poka Yoke 15 25. Office Kaizen 26. A. Kaizen 27. A. Transport 28. B. “ Motion” as one of the Waste in 7 wastes 16 CHAPTER 3 : WASTE ELIMINATION Q-1 Red tags are first used in what step of 5S? A.