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






2. 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


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






4. 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.






5. 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






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






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






8. 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.






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






10. 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






11. 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.






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






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






14. An interdepartmental management activity to realize QCD.






15. 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


16. 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






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


18. 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.






19. 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.






20. 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.






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






22. 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.






23. 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.






24. 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






25. 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


26. Japanese word meaning strain and difficulty.






27. 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.






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


29. Innovate to meet requirements and increase productivity






30. 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.






31. 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






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


33. 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.






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






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






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






37. 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






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






39. 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.






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






41. 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:






42. 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.






43. 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






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






45. 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.






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






47. 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.






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






49. Standardize an operation and activities






50. 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