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






2. 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.






3. 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






4. 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






5. 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.






6. An interdepartmental management activity to realize QCD.






7. 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.






8. 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






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






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






11. The opposite of pull production. The previous process produces as much as it can without regard for to the actual requirements of the next process and sends them to the next process whether there is a need or not.






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






13. 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.






14. 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


15. 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.






16. 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






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






18. Japanese word meaning irregularity or variability.






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






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






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






22. Innovate to meet requirements and increase productivity






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






24. One of the basic pillars of just-in-time production system. In the flow production - machines are arranged in the order of processing so that the work piece flows between processes without interruption and stagnation.






25. 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






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






27. 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.






28. 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






29. 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


30. 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:






31. 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






32. 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






33. Standardize an operation and activities






34. Shewart cycle - Deming cycle - PDCA






35. One of the basic requirements of a JIT production system. THe previous process produces only as many products as are consumed by the following process.






36. 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.






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






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






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






40. 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.






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






42. Gauge measurements against requirements






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


44. 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.






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






46. Continue cycle ad infinitum






47. 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.






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


49. 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


50. 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