Quiz 6 – Root Cause and Lea Improvement

What is the primary purpose of Root Cause Analysis (RCA)? *

To document every symptom without investigating causes

To identify underlying causes of a problem so effective corrective action can be developed

To increase final inspection regardless of the problem

To assign responsibility to the person closest to the failure

Which statement best describes the 5 Whys technique? *

It requires exactly five questions for every problem

It repeatedly asks why to explore a causal chain until a meaningful, actionable cause is reached

It assigns numerical risk ratings to failure modes

It is used only for potential future failures

In FMEA, what does Severity primarily represent? *

How often a failure occurs

How easily a failure can be detected

The significance of the effect if the failure occurs

The cost of performing the control

In traditional FMEA, a failure mode has Severity = 8, Occurrence = 5, and Detection = 4. What is its RPN? *

160

320

Which statement about traditional RPN is most accurate? *

Every combination producing the same RPN represents identical risk

RPN can help prioritize attention but does not fully describe the nature of risk

RPN eliminates the need to consider Severity separately

RPN is calculated by adding Severity, Occurrence, and Detection

Which Lean tool provides an end-to-end visual representation of material and information flow? *

5 S

Kanban

Value Stream Mapping

FMEA

Which of the following is an example of Overproduction waste? *

Producing items before they are required by downstream demand

Walking to retrieve a frequently used tool

Correcting a defective product

Cleaning a work area

Which sequence correctly represents the five stages of 5S? *

Sort, Set in Order, Shine, Standardize, Sustain

Select, Simplify, Study, Standardize, Sustain

Sort, Schedule, Shine, Stabilize, Sustain

Set in Order, Sort, Standardize, Shine, Sustain

A process has 420 minutes of available production time per day and customer demand of 140 units per day. What is the takt time? *

2 minutes per unit

3 minutes per unit

4 minutes per unit

6 minutes per unit

What is the fundamental principle of a Kanban pull system? *

Upstream production is always based on the maximum possible capacity

Downstream demand or consumption triggers upstream replenishment

All inventory must be eliminated immediately

Every process should produce as much as possible before stopping

What is the main purpose of a WIP limit in a Kanban system? *

To increase the amount of unfinished work in the process

To restrict work in process so flow can improve and excessive queues can be avoided

To replace all process performance measures

To guarantee that every task is completed immediately

Which statement best distinguishes a current-state VSM from a future-state VSM? *

Current-state maps proposed improvements; future-state maps historical performance

Current-state maps actual present flow; future-state maps a proposed improved flow

Both maps must show exactly the same process conditions

Future-state maps are used only for calculating RPN