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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 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.






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






3. 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.






4. An interdepartmental management activity to realize QCD.






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






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






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


8. 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






9. 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.






10. 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






11. 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.






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






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






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






15. Innovate to meet requirements and increase productivity






16. 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






17. Japanese word meaning strain and difficulty.






18. 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.






19. 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:






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


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. Standardize an operation and activities






23. 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.






24. 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


25. 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






26. 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






27. 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






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






29. 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.






30. Japanese word meaning irregularity or variability.






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






32. 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


33. 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.






34. Gauge measurements against requirements






35. 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






36. Shewart cycle - Deming cycle - PDCA






37. 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.






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






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






40. 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.






41. 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.






42. 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.






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


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






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






46. 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.






47. 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.






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






49. One of the basic pillars of just-in-time production system. In the flow production - machines are arranged in the order of processing so that the work piece flows between processes without interruption and stagnation.






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