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Test your basic knowledge |
Gemba Kaizen
Start Test
Study First
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. 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.
3rd Kaizen step
Store room
JIT (just-in-time)
Pareto chart
2. An optimum combination of man - machine - and material. The three elements of standardized work are take time - work sequence - and standard work-in-process.
Don't get it - don't make it - don't send it
Kosu
Total quality control
Standardized work
3. The application of statistical techniques to control a process. Often the term 'statistical quality control' is used interchangeably.
AQL
SDCA
Don't get it - don't make it - don't send it
Statistical process control (SPC)
4. 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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5. Continue cycle ad infinitum
5th Kaizen step
SDCA
Kaizen concepts
5 Kaizen Elements
6. The tangible objects found at gemba such as work pieces - rejects - jigs and tools - and machines.
Standards
Cost
Gembutsu
Conformance
7. 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
Five S's (5S)
Simultaneous realization of QCD
Ishikawa (fishbone) diagram
5 Whys
8. 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.
Store room
Standardization
SDCA
Standards
9. 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:
Muda
JK (jishu kanri)
5 Kaizen Elements
Flow Production
10. 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.
Failure Tree Analysis (FTA)
PDCA
JIT (just-in-time)
Ask why five times
11. 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
Flow Production
Pareto chart
AQL
Quality
12. 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.
Go to gemba
Total quality control
Cycle time
Flow Production
13. 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.
Three M's in gemba
AQL
Total quality control
Push production
14. Standardize-Do-Check-Act - the basic steps to be followed to maintain the current status.
Three K's (3K)
SDCA
QF
Control chart
15. Examining tangible objects in gemba when attempting to determine the root cause of problems.
Check gembutsu
QCDMS
Muri
JK (jishu kanri)
16. Measure the standardized operation (find cycle time and amount of in-process inventory)
Five S's (5S)
Cycle time
2nd Kaizen step
QCD
17. Shewart cycle - Deming cycle - PDCA
Standardized work
Other cycles
Standardization
1st Kaizen step
18. Major systems that must be established to attain a world class status. TQM - JIT production system - TPM - Policy deployment - Suggestion system - Small-group activities.
Hiyari report
Cycle time
Takt time
Kaizen systems
19. 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
Kaizen concepts
4th Kaizen step
Kanban
1st Kaizen step
20. A device that stops a machine whenever a defective product is produced.
AQL
QCDMS
Jidhoka (autonomation)
Kaizen concepts
21. Japanese word meaning irregularity or variability.
Muda
Three M's in gemba
Suggestion system
Mura
22. The three major resources to be managed in gemba - manpower - material - and machine.
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23. Acceptable Quality Level s a practice between customers and suppliers that allows suppliers to deliver a certain percentage of rejects by paying penalties.
Push production
5 Whys
AQL
Flow Production
24. 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
Five M's (5M)
Kaizen story
Go to gemba
Cycle time
25. 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
2nd Kaizen step
Simultaneous realization of QCD
Standardized work
Five M's (5M)
26. Standardize - Measure - Gauge - Innovate - Ad infinitum
Pareto chart
Kaizen Cycle
AQL
Push production
27. Gauge measurements against requirements
Total productive maintenance (TPM)
Ask why five times
3rd Kaizen step
Visual management
28. 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.
Visual management
Three K's (3K)
Hiyari report
Cost
29. Kaizen and management; Process versus result; Following the PDCA/SDCA; Putting quality first; Speaking with data; Treating the next process as the customer.
Kaizen story
Push production
Kaizen concepts
Takt time
30. A method for managing resources in gemba - specifically those know as '5M' - manpower - machine - material - method - and measurement.
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31. 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
Total quality control
Total productive maintenance (TPM)
SDCA
Five M's (5M)
32. 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
QF
Hiyari KYT
Pareto chart
Simultaneous realization of QCD
33. 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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34. The actual time taken by an operator to process a piece of product
QCD
Cycle time
Standards
Jidhoka (autonomation)
35. 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.
5 Kaizen Elements
Kosu
QF
Other cycles
36. 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
Kosu
QF
Morning market
Jidhoka (autonomation)
37. 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.
Statistical quality control (SQC)
5th Kaizen step
One-piece flow
Pull production
38. Only one work piece is allowed to flow from process to process to minimize muda in a JIT production system.
Standards
QCD
One-piece flow
Heinrich's Law
39. 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.
Hiyari report
Morning market
Gemba
Cost
40. 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.
AQL
Kaizen concepts
Three K's (3K)
JK (jishu kanri)
41. Muda (waste) - mura (irregularity) - and muri (strain).
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42. An affirmative indication or judgement that a product or service has met the requirements of a relevant specification - contract - or regulation.
Muda
3rd Kaizen step
Kaizen story
Conformance
43. Plan-Do-Check-Act - the basic steps to be followed in making continual improvement.
Kaizen story
Quality
Store room
PDCA
44. 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
Don't get it - don't make it - don't send it
Suggestion system
FMEA
Quality circles
45. Standardize an operation and activities
PDCA
Kanban
Pareto chart
1st Kaizen step
46. 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.
QCDMS
Five golden rules of gemba management
Ishikawa (fishbone) diagram
Total quality control
47. A Japanese word meaning 'real place' - now adapted in management terminology to mean the 'workplace' or that place where value is added.
Pareto chart
Heinrich's Law
Gemba
Cost
48. 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.
FMEA
Go to gemba
4th Kaizen step
Push production
49. 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.
Mura
Push production
Conformance
Flow Production
50. Japanese word meaning strain and difficulty.
Standardized work
One-piece flow
Go to gemba
Muri