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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. An interdepartmental management activity to realize QCD.






2. 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






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

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5. 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






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






7. Standardize an operation and activities






8. 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.






9. 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.






10. 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.






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






12. 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.






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






14. Innovate to meet requirements and increase productivity






15. 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






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






17. Gauge measurements against requirements






18. 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.






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

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20. 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






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






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






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.






24. 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.






25. Continue cycle ad infinitum






26. 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






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

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28. 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






29. 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.






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






31. Japanese word meaning irregularity or variability.






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






33. 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






34. Japanese word meaning strain and difficulty.






35. 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.






36. 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.






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






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






39. 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.






40. 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






41. 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.






42. 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:






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






44. 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.






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






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






47. 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.






48. 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.






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






50. 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