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Gemba Kaizen

Subjects : certifications, kaizen
Instructions:
  • Answer 50 questions in 15 minutes.
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  • 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. Standardize - Measure - Gauge - Innovate - Ad infinitum






2. In Japan - the suggestion system is a highly integrated part of individual-oriented kaizen. The Japanese-style suggestions systems emphasizes morale-boosting benefits and positive employee participation over the economic and financial incentives that






3. 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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4. Japanese word meaning irregularity or variability.






5. 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






6. 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






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






8. Continue cycle ad infinitum






9. 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.






10. 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






11. Gauge measurements against requirements






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

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13. 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






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






16. 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.






17. Standardize an operation and activities






18. An interdepartmental management activity to realize QCD.






19. 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.






20. 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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21. 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.






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






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






24. Japanese word meaning strain and difficulty.






25. 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.






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






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






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






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






30. 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.






31. 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






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






34. 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.






35. 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.






36. 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.






37. 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






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

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






40. Innovate to meet requirements and increase productivity






41. 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.






42. 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.






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






45. 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:






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






47. 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






48. 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






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

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50. 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.







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