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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 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.






2. 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.






3. 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






4. 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.






5. 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.






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






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

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






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. 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






12. 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






13. An interdepartmental management activity to realize QCD.






14. Japanese word meaning irregularity or variability.






15. 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.






16. Japanese word meaning strain and difficulty.






17. 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:






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






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






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






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






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

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






24. 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.






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






26. 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.






27. Continue cycle ad infinitum






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 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.






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






31. 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.






32. 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






33. 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.






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






35. 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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36. 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.






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






38. 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






39. Shewart cycle - Deming cycle - PDCA






40. 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






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






42. 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.






43. 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






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






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

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






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. 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.






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






50. Standardize an operation and activities







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