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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. Kaizen and management; Process versus result; Following the PDCA/SDCA; Putting quality first; Speaking with data; Treating the next process as the customer.
QCD
Statistical quality control (SQC)
Kaizen concepts
Pareto chart
2. 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
Value analysis (VA)
Pull production
SDCA
Delivery
3. 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.
Kanban
Flow Production
Go to gemba
SDCA
4. 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.
Five S's (5S)
Ishikawa (fishbone) diagram
Store room
5th Kaizen step
5. Only one work piece is allowed to flow from process to process to minimize muda in a JIT production system.
One-piece flow
Kaizen Cycle
Delivery
Other cycles
6. Standardize-Do-Check-Act - the basic steps to be followed to maintain the current status.
Cost
SDCA
Muda
Push production
7. Refers to the practice of anticipating danger in advance and taking steps to avoid it.
Five M's (5M)
Takt time
Hiyari KYT
Suggestion system
8. 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.
Three K's (3K)
Store room
Control chart
Hiyari KYT
9. Standardize - Measure - Gauge - Innovate - Ad infinitum
Morning market
Standards
Push production
Kaizen Cycle
10. 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
11. An interdepartmental management activity to realize QCD.
Check gembutsu
Conformance
Quality
Cross-funtional management
12. 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
SDCA
Kaizen Cycle
Simultaneous realization of QCD
Other cycles
13. 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.
Gembutsu
Heinrich's Law
QCD
Morning market
14. The three major resources to be managed in gemba - manpower - material - and machine.
15. 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.
Mura
Hiyari report
PDCA
Don't get it - don't make it - don't send it
16. 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.
Kanban
Total quality control
Statistical quality control (SQC)
Delivery
17. Measure the standardized operation (find cycle time and amount of in-process inventory)
Five M's (5M)
2nd Kaizen step
Five golden rules of gemba management
Three M's in gemba
18. The actual time taken by an operator to process a piece of product
Check gembutsu
Cycle time
Three M's in gemba
Ishikawa (fishbone) diagram
19. In gemba - oftern Morale (M) and Safety (S) are added to QCD as a target to be achieved.
Gemba
3rd Kaizen step
QCDMS
Three M's (3M)
20. 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
Cycle time
Kosu
Visual management
Statistical quality control (SQC)
21. Teamwork - Personal discipline - Improved morale - Quality circles - Suggestions for improvement
2nd Kaizen step
Kosu
5th Kaizen step
5 Kaizen Elements
22. 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
1st Kaizen step
5 Kaizen Elements
Delivery
Kosu
23. Acceptable Quality Level s a practice between customers and suppliers that allows suppliers to deliver a certain percentage of rejects by paying penalties.
AQL
3rd Kaizen step
Kaizen Cycle
Ishikawa (fishbone) diagram
24. 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.
Kaizen Cycle
Morning market
Pull production
FMEA
25. The application of statistical techniques to control a process. Often the term 'statistical quality control' is used interchangeably.
2nd Kaizen step
Statistical process control (SPC)
Failure Tree Analysis (FTA)
Value analysis (VA)
26. Shewart cycle - Deming cycle - PDCA
Gembutsu
QCDMS
3rd Kaizen step
Other cycles
27. Plan-Do-Check-Act - the basic steps to be followed in making continual improvement.
Pull production
PDCA
1st Kaizen step
Jidhoka (autonomation)
28. 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
Quality
Ishikawa (fishbone) diagram
Muri
Pareto chart
29. 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.
Pull production
Muda
3rd Kaizen step
Failure Tree Analysis (FTA)
30. Major systems that must be established to attain a world class status. TQM - JIT production system - TPM - Policy deployment - Suggestion system - Small-group activities.
Kaizen concepts
Heinrich's Law
Kaizen systems
Five M's (5M)
31. Examining tangible objects in gemba when attempting to determine the root cause of problems.
Three K's (3K)
Check gembutsu
Hiyari report
Ishikawa (fishbone) diagram
32. 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.
Visual management
Statistical quality control (SQC)
JIT (just-in-time)
Suggestion system
33. 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
34. Standardization is one of the three foundations of gemba kaizen activities and means the documentation of the best way to do the job.
Mura
Total productive maintenance (TPM)
Standardization
1st Kaizen step
35. A method for managing resources in gemba - specifically those know as '5M' - manpower - machine - material - method - and measurement.
36. A device that stops a machine whenever a defective product is produced.
Muda
Jidhoka (autonomation)
Hiyari KYT
Three M's in gemba
37. 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
Kaizen systems
Quality circles
Push production
PDCA
38. 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.
Suggestion system
Total productive maintenance (TPM)
5 Kaizen Elements
Takt time
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.
Cycle time
QCD
Suggestion system
PDCA
40. 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
Kaizen systems
5 Whys
Kaizen story
PDCA
41. 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
Don't get it - don't make it - don't send it
Statistical process control (SPC)
Five S's (5S)
Kaizen story
42. 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.
Ishikawa (fishbone) diagram
Kaizen story
Kaizen Cycle
Cost
43. 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
Visual management
Pareto chart
AQL
Three M's (3M)
44. 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
5 Whys
Kanban
Standardized work
Other cycles
45. A commonsense principle of determining the root cause of a problem.
QF
5th Kaizen step
Conformance
Ask why five times
46. A Japanese word meaning 'real place' - now adapted in management terminology to mean the 'workplace' or that place where value is added.
Go to gemba
Other cycles
Five golden rules of gemba management
Gemba
47. 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
SDCA
Suggestion system
Total quality control
Gemba
48. 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.
QF
JIT (just-in-time)
Five golden rules of gemba management
2nd Kaizen step
49. 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.
Five golden rules of gemba management
Quality circles
Takt time
Standards
50. Innovate to meet requirements and increase productivity
Statistical quality control (SQC)
5 Whys
4th Kaizen step
Kaizen concepts