Applied assessment — lean flow and structured improvement

Module quiz

8 questions on Module 3 — Lean Six Sigma for Industrial Engineering. Answer them all, then check your score before moving on. 6 correct or more is a pass. Your best score is saved on this device, and to your account when you are signed in. This is a self-check, not an accredited assessment.

1. 1. Bundles of cut parts sit two days between cutting and sewing. Which waste is that, and what does it cost?

   Motion; it tires the operatorsInventory and waiting; it ties up cash, hides defects until later and lengthens the response to a problemOver-processing; it adds operationsNo waste, because the line is never starved

2. 2. What does a value stream map show that a line layout does not?

   Machine positionsWhere time is spent across the whole flow, including the waiting between steps and the information that triggers each oneOperator skill levelsThe garment specification

3. 3. In DMAIC, what belongs in the Measure phase?

   Choosing the solutionEstablishing a trustworthy baseline, including checking that the measurement system is reliableTraining the operatorsWriting the standard operating procedure

4. 4. A team proposes a solution in the first meeting, before any data. What is the main risk?

   The solution will be too expensiveIt fixes a symptom or the wrong cause, and the problem returns after the attention moves onThe buyer will not approve itIt takes longer to implement

5. 5. Which pair of measures shows a real productivity gain rather than a shifted cost?

   Output per hour and overtime hours togetherOutput aloneEfficiency alonePieces shipped alone

6. 6. What makes a 5S or workplace-organisation change stick?

   A launch eventA standard, a short routine check and a named owner, so the state is maintained rather than restored before auditsA photograph on the notice boardA one-off deep clean

7. 7. Single-piece flow is proposed on a line making a complex jacket. What is the honest caution?

   It always increases outputIt exposes imbalance immediately and needs a well-balanced line, multi-skilled operators and reliable machines, or output falls at firstIt removes the need for quality checksIt only suits knits

8. 8. An improvement is signed off with a 12 per cent efficiency gain measured on one day. What is missing?

   The buyer's approvalEvidence that the gain holds over enough production, with the standard updated so the new method is what is actually runA financial estimateA photograph of the change