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






2. 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.






3. 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.






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






5. 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






6. 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






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






8. 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.






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






10. 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






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

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12. 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.






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






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






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






17. 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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18. Continue cycle ad infinitum






19. 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.






20. 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






21. Standardize - Measure - Gauge - Innovate - Ad infinitum






22. 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.






23. 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.






24. Japanese word meaning irregularity or variability.






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

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26. 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






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






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






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. 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






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






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






33. 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.






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






35. 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






36. 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.






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

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38. 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






39. 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.






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






41. 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.






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






43. 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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44. 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.






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






46. 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.






47. 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






48. 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.






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






50. Shewart cycle - Deming cycle - PDCA