10 exam-style questions with answers and explanations, straight from our 1,030-question bank. Tap an answer to check yourself. When you're ready, take the scored version in the free practice test.
These 10 free LGC questions are organized by exam domain, so you can see how each part of the Lean Gold Certification blueprint is tested. Reveal the answer and explanation under each question.
A cell redesign allows five operators to meet demand previously requiring six. Another value stream has an approved vacancy, and the released operator can qualify through cross-training. Employees are watching how leadership handles the change. Which decision is most likely to preserve their willingness to participate in future kaizen?
Correct answer: A - Implement the redesign and cross-train the released operator for the open position.
During a gemba walk at a U.S. plant, a supervisor sees an operator about to reach inside a hydraulic press to clear a jam. The emergency-stop button has been pressed, but electrical and hydraulic energy remain connected. Lockable energy-isolating devices are available, yet no energy-control procedure has been applied. What must happen before anyone reaches into the press?
Correct answer: A - An authorized employee must isolate and lock out energy sources, control stored energy, and verify isolation.
'Moving the kit rack should remove the delay,' a team leader predicted. During the trial, walking time fell, but orders still waited for the same missing component. In the next Coaching Kata conversation, which question would most directly strengthen the leader's scientific thinking?
Correct answer: D - What did the result teach you about the obstacle preventing orders from moving?
Two automated fastening stations detect out-of-specification torque. Station X illuminates a red light but advances the assembly unless an operator intervenes. Station Y retains the assembly and prevents the next cycle until the abnormality is addressed. The capability added at Station Y is primarily:
Correct answer: D - Jidoka: abnormality detection is coupled with stopping the process and preventing defects from advancing.
A manufacturer's strategic priority is shorter order-to-delivery lead time. Sales proposes smaller, more frequent releases, while production proposes longer campaigns to improve machine utilization. Each proposal meets its department's targets. During hoshin kanri deployment, how should these competing plans be reconciled?
Correct answer: C - Use catchball to agree on methods and measures that support the end-to-end lead-time objective.
At a tier-1 meeting, a team reports that its replenishment route missed a scheduled stop. The needed material is in the local supermarket, and the team leader has the authority and trained staff to restore supply. The delay can be recovered within the shift without affecting other areas. A manager proposes transferring every red item to the plant leadership team. For this issue, ownership should:
Correct answer: B - Remain with the team leader, with completion checked at the agreed follow-up.
Daily customer consumption is steady, but a buyer holds replenishment requests for a monthly ordering run. Stockouts occur while requests wait; large receipts then leave excess stock. The supplier already supports small batches and daily deliveries at unchanged freight cost. Which policy change removes the demand distortion seen by the supplier?
Correct answer: B - Send frequent replenishment signals based on actual withdrawals and the agreed replenishment lead time.
The morning review of a packaging line shows 450 minutes of scheduled production time, excluding breaks; 90 minutes lost to breakdowns and changeovers; and an ideal rate of 10 units per minute. The line produced 3,240 units, of which 3,078 were good without rework. Which assessment correctly pairs overall equipment effectiveness (OEE) with the largest measured time-loss category?
Correct answer: D - 68.4% OEE; breakdowns and changeovers account for the largest time loss.
An accounts-payable process has a cycle-time control chart centered at 5.1 days. Thirty consecutive observations show no control-limit violations or nonrandom patterns, but the agreed service requirement is completion within 4 days. The director asks for a separate special-cause investigation whenever an invoice takes more than 4 days. What does the evidence support instead?
Correct answer: C - Improve the underlying process; statistical stability does not establish acceptable customer performance.
A planned finished-goods inventory reduction leaves a manufacturer shipping more units than it produces. Customer shipment volume, prices, and conversion spending are unchanged, yet reported profit under absorption costing declines. The controller must distinguish the effect of inventory reduction from a deterioration in operations. Which analysis is most useful?
Correct answer: A - Separate overhead released from inventory from changes in current value-stream operating costs.
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