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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. 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






3. 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.






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

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






7. 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






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






9. 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.






10. 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.






11. 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






12. 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






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






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






15. 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.






16. 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.






17. 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.






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

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






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






21. 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.






22. 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:






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






24. Standardize an operation and activities






25. 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.






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






27. 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






28. 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.






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






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






31. 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.






32. 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.






33. 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






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






36. Japanese word meaning irregularity or variability.






37. 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






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

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






40. Innovate to meet requirements and increase productivity






41. 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.






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






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






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






45. 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.






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






47. 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






48. An interdepartmental management activity to realize QCD.






49. Japanese word meaning strain and difficulty.






50. 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.