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






2. 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






3. Gauge measurements against requirements






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






5. Japanese word meaning strain and difficulty.






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






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






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






10. Continue cycle ad infinitum






11. 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.






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






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

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14. 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.






15. 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.






16. 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.






17. Innovate to meet requirements and increase productivity






18. 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






19. 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






20. 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.






21. 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.






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






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






24. Shewart cycle - Deming cycle - PDCA






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






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






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






28. Japanese word meaning irregularity or variability.






29. 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






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






31. 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.






32. 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.






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






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






35. 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






36. 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.






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






38. 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.






39. 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.






40. 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.






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






42. 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






43. 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






44. 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.






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

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






47. 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.






48. Standardize an operation and activities






49. 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.






50. 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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