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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. 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.






2. 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.






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






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






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






7. 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.






8. 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






9. Japanese word meaning strain and difficulty.






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






11. 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






12. 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.






13. 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






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

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15. Gauge measurements against requirements






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






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






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

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






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






21. 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






22. 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.






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






24. 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.






25. 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.






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






27. Innovate to meet requirements and increase productivity






28. 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.






29. An interdepartmental management activity to realize QCD.






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






31. 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






32. 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






33. 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.






34. 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.






35. 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:






36. Continue cycle ad infinitum






37. Shewart cycle - Deming cycle - PDCA






38. 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.






39. 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.






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






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






42. 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.






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






44. 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






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






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






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






48. 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.






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






50. 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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