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Test your basic knowledge |
Gemba Kaizen
Start Test
Study First
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. Only one work piece is allowed to flow from process to process to minimize muda in a JIT production system.
One-piece flow
Other cycles
Kaizen concepts
AQL
2. An optimum combination of man - machine - and material. The three elements of standardized work are take time - work sequence - and standard work-in-process.
Gembutsu
Standardized work
Other cycles
Mura
3. Kaizen and management; Process versus result; Following the PDCA/SDCA; Putting quality first; Speaking with data; Treating the next process as the customer.
Kaizen concepts
Standardized work
Five M's (5M)
1st Kaizen step
4. 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.
FMEA
5 Whys
Morning market
Three K's (3K)
5. 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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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.
Statistical quality control (SQC)
Pareto chart
4th Kaizen step
Delivery
7. In gemba - oftern Morale (M) and Safety (S) are added to QCD as a target to be achieved.
QCDMS
One-piece flow
PDCA
5 Kaizen Elements
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
Three M's in gemba
Pareto chart
Kaizen story
Cost
9. Standardize - Measure - Gauge - Innovate - Ad infinitum
Three M's in gemba
Kaizen Cycle
Pull production
Cost
10. 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:
Kaizen concepts
Muda
FMEA
2nd Kaizen step
11. 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.
Five S's (5S)
Ishikawa (fishbone) diagram
Gembutsu
Hiyari KYT
12. 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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13. 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.
Kanban
JIT (just-in-time)
Other cycles
Three M's (3M)
14. The tangible objects found at gemba such as work pieces - rejects - jigs and tools - and machines.
Conformance
SDCA
Gembutsu
3rd Kaizen step
15. Measure the standardized operation (find cycle time and amount of in-process inventory)
Value analysis (VA)
2nd Kaizen step
Gemba
Delivery
16. 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
Kanban
Kaizen concepts
Five golden rules of gemba management
Quality
17. Major systems that must be established to attain a world class status. TQM - JIT production system - TPM - Policy deployment - Suggestion system - Small-group activities.
Suggestion system
Kaizen systems
Heinrich's Law
Ask why five times
18. 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.
SDCA
1st Kaizen step
Store room
JIT (just-in-time)
19. 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.
3rd Kaizen step
Hiyari report
Hiyari KYT
Standardized work
20. 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.
5 Whys
Delivery
Pull production
Cost
21. 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.
Failure Tree Analysis (FTA)
2nd Kaizen step
Three K's (3K)
Control chart
22. The application of statistical techniques to control a process. Often the term 'statistical quality control' is used interchangeably.
Kosu
Failure Tree Analysis (FTA)
Hiyari report
Statistical process control (SPC)
23. 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.
Kaizen Cycle
Statistical quality control (SQC)
Control chart
Cycle time
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.
QCDMS
FMEA
3rd Kaizen step
QCD
25. Continue cycle ad infinitum
Go to gemba
5th Kaizen step
2nd Kaizen step
Conformance
26. 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.
Mura
Pull production
Muri
2nd Kaizen step
27. 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.
JK (jishu kanri)
Control chart
3rd Kaizen step
Three M's in gemba
28. 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.
Other cycles
Ask why five times
QCD
QF
29. 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
5 Kaizen Elements
Failure Tree Analysis (FTA)
Suggestion system
QCDMS
30. Shewart cycle - Deming cycle - PDCA
Other cycles
Simultaneous realization of QCD
Hiyari KYT
4th Kaizen step
31. A method for managing resources in gemba - specifically those know as '5M' - manpower - machine - material - method - and measurement.
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32. Gauge measurements against requirements
Hiyari report
3rd Kaizen step
Kanban
Jidhoka (autonomation)
33. A Japanese word meaning 'real place' - now adapted in management terminology to mean the 'workplace' or that place where value is added.
Kaizen story
Don't get it - don't make it - don't send it
Gemba
AQL
34. 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.
Store room
5th Kaizen step
Standardized work
Five golden rules of gemba management
35. The actual time taken by an operator to process a piece of product
Go to gemba
Takt time
Cycle time
Failure Tree Analysis (FTA)
36. 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
Failure Tree Analysis (FTA)
Statistical quality control (SQC)
Quality
Kaizen systems
37. Innovate to meet requirements and increase productivity
SDCA
4th Kaizen step
Heinrich's Law
AQL
38. Standardize-Do-Check-Act - the basic steps to be followed to maintain the current status.
SDCA
Flow Production
Five S's (5S)
Standardization
39. 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
QCDMS
Five S's (5S)
Kosu
Standardized work
40. 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.
Suggestion system
Pareto chart
Total quality control
Kaizen concepts
41. Plan-Do-Check-Act - the basic steps to be followed in making continual improvement.
3rd Kaizen step
JK (jishu kanri)
PDCA
Morning market
42. 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
Quality circles
Control chart
FMEA
5 Whys
43. Teamwork - Personal discipline - Improved morale - Quality circles - Suggestions for improvement
Morning market
Gemba
Delivery
5 Kaizen Elements
44. 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
SDCA
Total productive maintenance (TPM)
Muda
QCDMS
45. Japanese word meaning strain and difficulty.
PDCA
Three K's (3K)
QF
Muri
46. Standardization is one of the three foundations of gemba kaizen activities and means the documentation of the best way to do the job.
Don't get it - don't make it - don't send it
Gemba
1st Kaizen step
Standardization
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
2nd Kaizen step
Push production
Value analysis (VA)
Visual management
48. 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.
Gemba
Visual management
Cost
Kaizen systems
49. An interdepartmental management activity to realize QCD.
Cross-funtional management
Jidhoka (autonomation)
Check gembutsu
Kosu
50. 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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