3M & 5 S: Improving Efficiency of Food Production
Self Test Questions
1. Reducing Cost through Waste Elimination involves genuine cost reduction, is more
acceptable to employees and impacts top and bottom line as compared to Cutting costs
which involves reduction of expenses and may be temporary and painful.
a. True
b. False
2. Waste, Strain, Inconsistency (Muda, Muri, Mura) are interdependent and eliminating
these should be the primary aim of an organisation to improve efficiency
a. True
b. False
3. Conveyance within the factory & Processing documents t calculat Inventory carrying costs
are some examples of Value-Added activities
a. True
b. False
4. Identify the Muda (Waste) in the rows below: ( e.g Muda of Defects, Waiting time,
Overproduction, Excess Inventory, Unnecessary transportation, Motions, Unnecessary
processing etc )
Type of Waste
Examples
Defects
Non budgeted scrap
Waste through High
Inventory
25% - 40% excess Packaging Material (20 days) despite 3 days lead
time
Waiting time
Waiting for Raw material to be issued
Unnecessary processing
Preparing sugar syrup manually, cooling, storing and then transferring
to blender at higher temperature
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Unnecessary transportation Transferring material in 1 tier instead of 2 tier trolley
Excess Inventory
Transactions not processed, Data which is not organized or fully
Utilized.
Motions
Repeated to and fro movement of the worker
5. 5S is an effective way of reducing Muda of Waiting
a. True
b. False
6. High Quantities of Work - In - Process may be a symptom of Line Inconsistency/ Line
Imbalance (Mura)
a. True
b. False
7. Zone wise identification of Waste, Strain, Inconsistency (3 M), followed by prioritisation
and team allocation is an effective practice to start eliminating 3 M
a. True
b. False
8. Transportation Waste may be caused by
a. Poor Plant Layout
b. Use of Batch Process
c. Long Lead times
d. Large storage areas
e. Scheduling Problems
f. All of The above (a-e)
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g. None of the above (a-e)
9. Some causes of Muda of Waiting may be:
a. Machine downtime
b. Lack of parts
c. Line stoppages
d. Long changeover time
e. Batch flow of material
f. All of The above (a-e)
g. None of the above (a-e)
10. The key purpose of workplace organisation through 5S is
a. reducing manual labour
b. reducing energy consumption
c. reducing environment pollution
d. to reduce waste
11. Sorting (1S) involves
a. Identifying a place for everything and keeping everything in place. In other words,
Prefixed quantities in prefixed locations with identifications, labels, directional signs
resulting in a ' Visual' factory.
b. Training, 5 S Audit, Sustaining
c. Segregating necessary from unnecessary, disposing what is not required and doing it at
stipulated frequency
d. Cleaning sorted items at stipulated frequencies as per cleaning schedules, responsibilities
and standardised methodologies.
12. Systematic Arrangement (2 S) involves
a. Training, 5 S Audit, Sustaining
b. Segregating necessary from unnecessary, disposing what is not required, doing it at
stipulated frequency
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c. Cleaning sorted items at stipulated frequencies as per cleaning schedules, responsibilities
and standardised methodologies.
d. Identifying a place for everything and keeping everything in place. In other words,
Prefixed quantities in prefixed locations with identifications, labels, directional signs thus
resulting in a ' Visual' factory/ workplace.
13. Self Discipline (5S) involves
a. Cleaning sorted items at stipulated frequencies as per cleaning schedules, responsibilities
and standardised methodologies.
b. Identifying a place for everything and keeping everything in place. In other words,
Prefixed quantities in prefixed locations with identifications, labels, directional signs
resulting in a ' Visual' factory.
c. Training, 5 S Audit, Sustaining by following standards
d. Segregating necessary from unnecessary, disposing what is not required, doing it at
stipulated frequency
14. Spic and Span (3 S)
a. Documenting and implementing Cleaning Procedures (What to clean, How, Who, When,
Where)
b. Identifying root causes of why things get dirty and doing the needful
c. Maintaining only the required number of items
d. Preventing Spillage and Leakage in the Workplace from machineries, utility lines, ceilings
etc
e. All of the above
15. The best way to identify 5S zones is to do it on the layout map so that every space is
covered under 5S
a. True
b. False
16. It is not necessary to cover Scrap Yard, Toilets and Garden/ Lawns of the workplace
under 5S Zones
a. True
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b. False
17. Fixed Point Photography and Worst Point Photography are effective ways to:
a. take action on defaulters
b. monitor 5S Progress and take improvement actions
c. None of the above
18. You would know that 5S is working in your workplace when you find
a. Visual Workplace
b. Reduced Search time for tools, records, documents
c. No unwanted items
d. No spillage and leakage from equipments, lines, ceilings etc
f. All of the above
19. Some useful tools for 5S are:
a. Cleaning schedules
b. Sorting frequency
c. 5S Maps with zones and responsibilities
d. 5S Audit schedules with checklists and allocated scores
e. All of the above
20. 3S (Spic and Span) involves:
a. Remove Unnecessary items
b. Reducing Search time of items
c. Cleaning in such a way so that flaws can be inspected
d. Standardising arrangements to avoid misplacing
e. Self Discipline
f. All of the above
21. Sorting means
a. Removing all items from the workplace that are not needed for current production
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b. Removing all items from the workplace that are not needed at all
22. What items should be covered under Red tagging?
a. Inventory
b. Equipments and Spare parts
c. Shelves
d. All of the above (a, b, c)
e. None of the above (a, b, c)
23. Best way to do Red tagging:
a. Do whole target area quickly
b. Do whole target area slowly
24. Practical Training on 5S in the Workplace is helpful to understand that 5S is not
Housekeeping but a tool to organise the workplace in such a way so that wastes are
reduced.
a. True
b. False
25. Redesigning the workplace layout to take advantage of ergonomics, may reduce Waste
of Motion
a. True
b. False
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