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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. 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.






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






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






4. 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.






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






6. 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.






7. 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.






8. 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






9. Kaizen and management; Process versus result; Following the PDCA/SDCA; Putting quality first; Speaking with data; Treating the next process as the customer.






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






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






12. 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.






13. 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.






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

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






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






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






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






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






20. 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.






21. Continue cycle ad infinitum






22. The top management must make certain that all levels of the com pay work to achieve Quality - Cost - and Delivery. The ultimate goal is to realize QCD simultaneously - but first of all - priority must be established among the three - quality always b






23. 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.






24. 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






25. 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.






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






27. 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






28. 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.






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






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

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






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

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33. Standardize an operation and activities






34. Innovate to meet requirements and increase productivity






35. 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






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






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






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






40. 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.






41. Japanese word meaning strain and difficulty.






42. 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.






43. 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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44. 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.






45. 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.






46. 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.






47. Japanese word meaning irregularity or variability.






48. Shewart cycle - Deming cycle - PDCA






49. 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






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