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Gemba Kaizen

Subjects : certifications, kaizen
Instructions:
  • Answer 50 questions in 15 minutes.
  • If you are not ready to take this test, you can study here.
  • Match each statement with the correct term.
  • Don't refresh. All questions and answers are randomly picked and ordered every time you load a test.

This is a study tool. The 3 wrong answers for each question are randomly chosen from answers to other questions. So, you might find at times the answers obvious, but you will see it re-enforces your understanding as you take the test each time.
1. A checklist for good housekeeping to achieve greater order - efficiency - and discipline in the workplace. It is derived from the Japanese words seiri - seiton - seiso - seiketsu - and shituke and adopted to the English equivalents of sort - straight


2. Plan-Do-Check-Act - the basic steps to be followed in making continual improvement.






3. Quality improvement or self-improvement study groups composed of small number of employees (ten or fewer). This group voluntarily performs improvement activities within the workplace - carrying out its work continuously as a part of a companywide pro






4. The application of statistical techniques to control a process. Often the term 'statistical quality control' is used interchangeably.






5. The theoretical time it takes to produce a piece of product ordered by the customer - as determined by dividing the total production time by the number of units to be produced.






6. Only one work piece is allowed to flow from process to process to minimize muda in a JIT production system.






7. In gemba - oftern Morale (M) and Safety (S) are added to QCD as a target to be achieved.






8. A method for cost reduction; it aims at reducing material and component costs at the upstream stages of designing and design reviews and involves cross-functional collaborations of product design - production engineering - quality assurance - and man






9. A commonsense principle of determining the root cause of a problem.






10. Measure the standardized operation (find cycle time and amount of in-process inventory)






11. A Japanese word meaning 'real place' - now adapted in management terminology to mean the 'workplace' or that place where value is added.






12. A device that stops a machine whenever a defective product is produced.






13. Innovate to meet requirements and increase productivity






14. Quality - Cost - and delivery is regarded as an ultimate goal of management. When management is successful in achieving QCD - both customer satisfaction and corporate success follow.






15. Examining tangible objects in gemba when attempting to determine the root cause of problems.






16. Teamwork - Personal discipline - Improved morale - Quality circles - Suggestions for improvement






17. The tangible objects found at gemba such as work pieces - rejects - jigs and tools - and machines.






18. The actual time taken by an operator to process a piece of product






19. Aims at maximizing equipment effectiveness throughout the entire life of the equipment. TPM involved everyone in all departments and at all levels; it motivates people for plant maintenance through small-group and autonomous activities - and involves






20. A chart with upper and lower control limits on which values of some statistical measures for a series of samples or subgroups are plotted. The chart frequently shows a central line to help detect a trend of plotted values toward either control limit.






21. The place where work-in-processes and supplies are stored in gemba. A store room is different from the normal warehouse since only standardized inventory is kept in the store room.






22. Gauge measurements against requirements






23. A diagram to show causes (process) and the effect (result). The diagram is used to determine the real cause(s) and is one of seven basic tools of problem solving.






24. Shewart cycle - Deming cycle - PDCA






25. A communication tool in the just-in-time system whenever a batch production is involved. A kanban - which means a sign board in Japanese - is attached to a given number of parts or products in the production line - instructing the delivery of a given






26. A daily routine at gemba that involved examining rejects made the previous day before the work begins so that countermeasures can be adopted as soon as possible - based on gemba-gembutsu principles.






27. Standardize an operation and activities






28. Standardize-Do-Check-Act - the basic steps to be followed to maintain the current status.






29. The Japanese word meaning 'waste' which - when applied to management of the workplace - refers to a wide range of non-value-adding activities. In gemba - there are only two types of activities: value adding and non-value adding. Eight types of muda:






30. A graphical tool for ranking causes from the most significant to the least significant. The Pareto principle (80:20) suggests that 80 percent of effects come from 20 percent of the possible causes. The Pareto chart is one of the seven basic tools of






31. An interdepartmental management activity to realize QCD.






32. Major systems that must be established to attain a world class status. TQM - JIT production system - TPM - Policy deployment - Suggestion system - Small-group activities.






33. A form of root cause analysis in which the user asks 'why' to a problem and its answer up to five (if needed) successive times






34. Failure Tree Analysis is used to analyze and avoid in advance any safety and reliability problems by identifying cause-and-effect relationships and probability of problems by using the tree diagram.






35. Refers to the specific man hours it takes to process one unit of product in a given process and is calculated by multiplying the number of workers involved in the process by the actual time it takes to complete the process - and dividing that by the






36. Refers to the practice of anticipating danger in advance and taking steps to avoid it.






37. An affirmative indication or judgement that a product or service has met the requirements of a relevant specification - contract - or regulation.






38. The three major resources to be managed in gemba - manpower - material - and machine.


39. Organized kaizen activities on quality involves everyone in a company - managers and workers - in a totally integrated effort tower kaizen at every level. Also referred to as Total Quality Management.






40. An optimum combination of man - machine - and material. The three elements of standardized work are take time - work sequence - and standard work-in-process.






41. Japanese word meaning strain and difficulty.






42. An effective management method to provide information and gembutsu in a clearly visible manner to both workers and managers so that the current state of operations and the target for kaizen are understood by everybody. It also helps people to identif






43. Jishu kanji means autonomous management in Japanese and refers to workers' participation in kaizen activities as part of their daily activities under the guidance of the line manager.






44. When used in the contact of QCD - the word cost usually refers to cost management - and not cost cutting. Cost management refers to managing various resources properly - and eliminating all sort of muda in such a way that the overall cost goes down.






45. A method for managing resources in gemba - specifically those know as '5M' - manpower - machine - material - method - and measurement.


46. Standardization is one of the three foundations of gemba kaizen activities and means the documentation of the best way to do the job.






47. The first principle of gemba kaizen. This is a reminder that whenever abnormality occurs - or whenever a manager wishes to know the current state of operations - he or she should go to gemba right away - since gemba is a source of all information.






48. A best way to do the job - namely - a set of policies - rules - directives - and procedures established by management for all major operations - which serve as guidelines that enable all employees to perform their jobs to assure good results.






49. Acceptable Quality Level s a practice between customers and suppliers that allows suppliers to deliver a certain percentage of rejects by paying penalties.






50. The scare report is a written form from a worker to a supervisor that reports a condition that is unsafe and could lead to quality problems and/or accident.