Lean Six Sigma Exam
Lean Tools & Waste Reduction Practice Questions
130 practice questions with detailed explanations — aligned to the Lean Six Sigma Exam.
Master Lean Tools & Waste Reduction to boost your score on the Lean Six Sigma Exam. Each question below mirrors the style and difficulty of real exam questions, complete with detailed explanations so you understand the why behind every answer. Work through all 130 questions, review any that trip you up, and use the related topics below to round out your preparation.
Q1.Which of the following is NOT one of the 8 wastes (DOWNTIME) in Lean?
A.DefectsB.OverproductionC.Non-utilized talentD.AutomationD. AutomationExplanation: The 8 Lean wastes are captured in DOWNTIME: Defects, Overproduction, Waiting, Non-utilized talent, Transportation, Inventory, Motion, Extra-processing. Automation is not a waste — it is often a tool to eliminate waste. The 8th waste (non-utilized talent) is sometimes omitted in the older TPS '7 wastes' model.
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Q2.A Value Stream Map (VSM) primarily helps a team:
A.Calculate process capability indicesB.Visualize all steps in a process and identify value-added vs. non-value-added activitiesC.Plot control limits on a production chartD.Design experiments to optimize input settingsB. Visualize all steps in a process and identify value-added vs. non-value-added activitiesExplanation: A Value Stream Map shows the complete flow of materials and information from raw material to customer, with cycle times, inventory levels, and wait times at each step. It distinguishes value-added from non-value-added (waste) activities, enabling targeted improvement. VSM is a core Lean tool typically used in the Analyse phase.
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Q3.In the 5S methodology, what does the third 'S' (Shine / Seiso) mean?
A.Sort and remove unnecessary items from the workplaceB.Systematically clean the workspace and equipmentC.Standardize the first three S's across all areasD.Sustain gains through ongoing auditsB. Systematically clean the workspace and equipmentExplanation: The 5S steps are: Sort (Seiri) — remove unneeded items; Set in order (Seiton) — organize what remains; Shine (Seiso) — clean and inspect; Standardize (Seiketsu) — create standards for the first three S's; Sustain (Shitsuke) — maintain discipline. Shine also serves as an inspection — cleaning reveals abnormalities like leaks and worn parts.
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Q4.Poka-yoke refers to:
A.A Japanese term for kaizen eventsB.Mistake-proofing — designing a process so errors are impossible or immediately obviousC.The pull production scheduling systemD.A visual management board showing work statusB. Mistake-proofing — designing a process so errors are impossible or immediately obviousExplanation: Poka-yoke (mistake-proofing or error-proofing) is a Lean technique developed by Shigeo Shingo. A poka-yoke prevents defects by making errors physically impossible (prevention type) or immediately detectable (detection type). Examples: USB connectors that only insert one way, a checklist that won't advance unless all fields are complete.
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Q5.What is kaizen?
A.A statistical method for setting control limitsB.A philosophy of continuous incremental improvement involving all employeesC.A type of kanban scheduling systemD.A Six Sigma tool for comparing means across multiple groupsB. A philosophy of continuous incremental improvement involving all employeesExplanation: Kaizen (Japanese: 改善, 'change for the better') is the philosophy of continuous, incremental improvement — small, frequent changes made by everyone, every day, at every level. Kaizen events (blitzes) are intensive, short-duration improvement workshops focused on a specific process area. Kaizen is a foundational element of the Toyota Production System.
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