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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. 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.






2. Japanese word meaning irregularity or variability.






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

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5. 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






6. 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






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






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






9. 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.






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

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






12. 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.






13. 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:






14. Innovate to meet requirements and increase productivity






15. 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.






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






17. 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.






18. An interdepartmental management activity to realize QCD.






19. 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.






20. 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.






21. 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






22. 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.






23. 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.






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






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






26. 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






27. 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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28. 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.






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






30. Standardize an operation and activities






31. Continue cycle ad infinitum






32. 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.






33. Gauge measurements against requirements






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






35. Japanese word meaning strain and difficulty.






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

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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. 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.






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






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






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






42. 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






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






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






45. 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.






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






47. 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.






48. 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






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






50. 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.