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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 system designed to achieve the best possible quality - cost - and delivery of products and services by eliminating all kinds of muda in a company's internal processes and deliver products just-in-time to meet customer's requirements.






2. 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.






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

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






5. 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.






6. The application of statistical techniques to control quality. Often used interchangeably with statistical process control - but includes acceptance sampling as well as statistical process control.






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






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






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






10. Innovate to meet requirements and increase productivity






11. Continue cycle ad infinitum






12. 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






13. Standardize - Measure - Gauge - Innovate - Ad infinitum






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

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15. An interdepartmental management activity to realize QCD.






16. Japanese word meaning strain and difficulty.






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






18. 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






19. 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.






20. Quality Function Deployment is a management approach to identify customer requirements first - and then work back through the stages of design - engineering - production - sales - and after-service of products.






21. 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.






22. In the context of QCD - quality refers to the quality of products or services delivered to the customer. In this instance - quality refers to the conformance to specifications and customer requirements. In a broader sense - quality refers to the qual






23. 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:






24. Muda (waste) - mura (irregularity) - and muri (strain).

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






26. A principle related to occurrence ratio of accidents with injuries. Heinrich expressed the ratio as follows: Serious injury:minor injury:no injury = 1:29:300. This equation expresses that when you see 1 person who was seriously injured by an accident

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






28. Failure Mode and Effect Analysis is an an analytical tool used to predict and eliminate in advance any potential design defect in new product by analyzing the effects of failure modes of component parts on the final product performance.






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






30. Gauge measurements against requirements






31. 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.






32. A set of the most practical reminders in implementing kaizen in gemba: (1)Go to gemba when problems arise; (2)check gembutsu; (3)take temporary measures on the spot; (4)find and eliminate the root cause; and (5)standardize to prevent recurrence.






33. A standardized problem-solving procedure to be used at each level of organization. Kaizen story has eight steps: (1)select a project - (2)understand current situations and set objectives - (3)analyze data to identify root causes - (4)establish counte






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






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






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






37. Standardize an operation and activities






38. 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.






39. When used in the contact of QCD - the word delivery refers to meeting both the delivery as well as the volume requirements of the customer.






40. The Japanese words referring to conventional perception of gemba - kiken (dangerous) - kitanai (dirty) - and kitsui (stressful) - in direct contrast to the idea of gemba being the place where real value is added and the source of ideas for achieving

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41. 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.






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






43. 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

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44. Shewart cycle - Deming cycle - PDCA






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






46. 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.






47. 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






48. A commonsense slogan to be implemented in gemba that puts into practice the belief that quality is the first priority in any program of QCD - for example - don't accept inferior quality from the previous process - don't make rejects in one's product

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49. 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.






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