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. What is level four of key 5?
1. Improvement activities are designed to increase equipment effectiveness by eliminating the '6 Big Losses' - 2. An autonomous maintenance program to be performed by equipment operators - 3. A planned maintenance system - 4. Training to improve the
Large scale improvement
Everyone understands the need for PM; PM has been implemented for the most important machines.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.


2. What is product flow charting?
One operator handling several machines or processes
Encourage the workers and get people ready to start working. To review what was done that day and get prepared for the next day's activities and goals.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Study the flow of a product through the various operations


3. What is preventive maintenance?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Time measuring
Each process must provide quality products in the desired amounts to their store so their next process customer can get exactly what is needed next. Taking from you what I need and the stocker replenishes it: shopping - Far less WIP here than with pu


4. What are the different types of motions required for performing an operation? (Type 1 motions)
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
It generates a payoff that covers the capital and human investment. The benefits of TPM can only be estimated but - nevertheless - should be based on life-cycle costing.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


5. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Time it takes to make one unit
Supervisors meet to work out time control issues


6. What did Frank Gilbreth do?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Made the basic elements of human motion (therbligs)
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Prevents equipment from breaking down or malfunctioning.


7. What is level 5 of key 10?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
It generates a payoff that covers the capital and human investment. The benefits of TPM can only be estimated but - nevertheless - should be based on life-cycle costing.


8. What is prevention maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Preventative maintenance - Prevention maintenance - Corrective prevention
Prevents equipment from breaking down or malfunctioning.


9. At level three of key 6 - what is the methodology employees have been trained to use?
Industrial engineering methodologies
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Quick changeover studies begin; some employees are learning how to implement single changeover.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


10. What is Industrial Engineering?
Manufacturing value analysis
It's hard because it deals with attitudes of employees.
Hands-on activity based on the facts - not opinion.
Each process must provide quality products in the desired amounts to their store so their next process customer can get exactly what is needed next. Taking from you what I need and the stocker replenishes it: shopping - Far less WIP here than with pu


11. What is level 4 of key 10?
Workers are conscientious about sticking to the work throughout the designated working areas.
Time control and commitment
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


12. What are the benefits of quick changeover for companies?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Eliminate certain processes that produce or create waste.
There is a shotgun approach to improvements; people have little concern for improving methods.


13. What is production leveling?
Time control and commitment
At least 10% of the projects have succeeded in establishing unmonitored one-cycle operation during the lunch break; at least 10% of office operations have one-page standards
You want to equalize your work loads in terms of your lot size - one-piece flow.
Encourage the workers and get people ready to start working. To review what was done that day and get prepared for the next day's activities and goals.


14. What is focused improvement?

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15. What is level two of key 6?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Zero monitor manufacturing
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


16. What is level 3 of key 10?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Preventative maintenance - Prevention maintenance - Corrective prevention
Supervisors meet to work out time control issues
Cycle time - work sequence - standard inventory


17. What is key #5?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
It analyzes the functions of individual manufacturing steps or motions and analyzes whether they add value to the product - Look at every step in your process and see if it adds value or not. If the answer is yes - can we improve it? If the answer i
Quick changeover technology


18. What is level three of key 5?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Knowledge - Job security - Safety - Simplicity
One operator handling several machines or processes
Match production volume to demand volume - Operate at the speed of the slowest machine - Standard intra-process inventories are always maintained - The machines work together to prevent overproduction - or stop or shut down after processing a standa


19. What is the purpose of Chronocyclegraphic analysis?
Run the machines into the ground
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Filming someone with a light on their finger that blinks at a pre-determined interval so you can see the movements to better improve the design.
Encourage the workers and get people ready to start working. To review what was done that day and get prepared for the next day's activities and goals.


20. What is an external setup element?
You have to communicate! Coordinate where the output is going to be stored.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Video tape a person doing this so they can review what they're doing and improve.
Can be done while the machine is still processing.


21. What is the purpose of Therblig analysis?
Zero monitor manufacturing
Helps you understand the facts as they are.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
1. Improvement activities are designed to increase equipment effectiveness by eliminating the '6 Big Losses' - 2. An autonomous maintenance program to be performed by equipment operators - 3. A planned maintenance system - 4. Training to improve the


22. What are the three pillars of lean systems?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
An approach that seeks to fully establish the conditions needed to prevent breakdowns. This approach starts by asking 'why?' repeatedly to discover root causes of breakdowns so that problems can be fixed at the source.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Can be done while the machine is still processing.


23. What is level 1 of key 10?

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24. What is the purpose of video analysis?

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25. What is preventative maintenance?
Identifying problems before they cause breakdowns.
Morning pep talk meetings are held everyday
You have to communicate! Coordinate where the output is going to be stored.
It provides pickup or transfer information - Provides production information - Prevents overproduction and excessive transport - Serves as a work order attached to the goods - Prevents defective products by identifying the process making the defectiv


26. What is cycle time?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Study the movement and motions of a worker or associate
Time it takes to make one unit
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


27. What is level 2 of key 9?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Hands-on activity based on the facts - not opinion.


28. What are the steps in motion study?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Contamination - inadequate lubrication - misoperation
Study the flow of a product through the various operations


29. What is key #8?
Time it takes to make one unit
Machines work together to prevent overproduction - it stops once it meets demands.
Coupled manufacturing
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


30. What is level one of key 7?
No one realizes that monitoring is waste - not work
Manufacturing value analysis
The production schedule determines how many products each process will turn out and send to the next process. Pushes them onto the customer whether they're ready for them or not.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


31. What are the three principles of prevention?
Work and break times are left to the workers' discretion
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
It generates a payoff that covers the capital and human investment. The benefits of TPM can only be estimated but - nevertheless - should be based on life-cycle costing.


32. What is level four of key 7?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Filming someone with a light on their finger that blinks at a pre-determined interval so you can see the movements to better improve the design.
1. Breakdown losses (function loss and function reduction) 2. Changeover losses 3. Idling and minor stoppage losses 4. Quality defects and rework (special cause and common cause) 5. Reduced speed losses 6. Start-up/yield losses
All machines can operate during lunch without monitoring and many operators can handle two or more machines


33. What is level 1 of key 9?
Manufacturing value analysis
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Run the machines into the ground
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


34. What is the trouble with large-lot production?
Filming someone with a light on their finger that blinks at a pre-determined interval so you can see the movements to better improve the design.
Inventory waste - Delay - Declining quality
Helps you understand the facts as they are.
There is a shotgun approach to improvements; people have little concern for improving methods.


35. What is key #9?
Maintaining equipment
Quick changeover studies begin; some employees are learning how to implement single changeover.
Eliminate certain processes that produce or create waste.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.


36. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
They are the result of poor arrangement - timing - and/or work methods. Are all cost and should be eliminated or reduced. (Search - find - select - proposition - hold)
Can only be done when the machine is stopped or shut down.


37. What is push production?

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38. What is level two of key 5?
Study the flow of a product through the various operations
Quick changeover studies begin; some employees are learning how to implement single changeover.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Filming someone with a light on their finger that blinks at a pre-determined interval so you can see the movements to better improve the design.


39. What is level five of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Morning pep talk meetings are held everyday
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Doubling productivity - Productivity = Output / TEE


40. What is the goal of motion study?
Study the flow of a product through the various operations
To eliminate the big 3.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.


41. What does manufacturing value analysis do?
It analyzes the functions of individual manufacturing steps or motions and analyzes whether they add value to the product - Look at every step in your process and see if it adds value or not. If the answer is yes - can we improve it? If the answer i
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Determining the life expectancy of components in order to replace them at the optimum time.
Filming someone with a light on their finger so you can see the movements to better improve the design.


42. What does TPM do?
Knowledge - Job security - Safety - Simplicity
Prevents equipment from breaking down or malfunctioning.
1. Breakdown losses (function loss and function reduction) 2. Changeover losses 3. Idling and minor stoppage losses 4. Quality defects and rework (special cause and common cause) 5. Reduced speed losses 6. Start-up/yield losses
Hands-on activity based on the facts - not opinion.


43. What are the three elements of the standard work sheet?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Cycle time - work sequence - standard inventory
Discovery is initiated by dissatisfaction - What needs to be improved? (PQCDSM checklist) - Analysis of current conditions - Identify major problem points - Create improvement plan - PDCA - Follow up/ Anchor Change
Helps you understand the facts as they are.


44. What are the functions and rules of kanban?
Continuous improvement of person and process
It generates a payoff that covers the capital and human investment. The benefits of TPM can only be estimated but - nevertheless - should be based on life-cycle costing.
Video tape a person doing this so they can review what they're doing and improve.
It provides pickup or transfer information - Provides production information - Prevents overproduction and excessive transport - Serves as a work order attached to the goods - Prevents defective products by identifying the process making the defectiv


45. What appears to be the primary metric in key 6?
Manufacturing value analysis
Identifying and repairing equipment problems before they cause breakdowns. Create a maintenance log for every machines. Then determine which machines are most important and in most need of PM and label these machines as 'Designated PM Equipment'.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Time measuring


46. What is the new product introduction loop?

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47. What is level 4 of key 9?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Maintaining equipment
Match production volume to demand volume - Operate at the speed of the slowest machine - Standard intra-process inventories are always maintained - The machines work together to prevent overproduction - or stop or shut down after processing a standa
1. Improvement activities are designed to increase equipment effectiveness by eliminating the '6 Big Losses' - 2. An autonomous maintenance program to be performed by equipment operators - 3. A planned maintenance system - 4. Training to improve the


48. What is level 3 of key 9?
Video tape a person doing this so they can review what they're doing and improve.
Time measuring
Operators know they must keep their machines in good condition and eliminate the three evils.
1. Improvement activities are designed to increase equipment effectiveness by eliminating the '6 Big Losses' - 2. An autonomous maintenance program to be performed by equipment operators - 3. A planned maintenance system - 4. Training to improve the


49. What is level five of key 8?
Cycle time - work sequence - standard inventory
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Workers are conscientious about sticking to the work throughout the designated working areas.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


50. What is the purpose of flowcharting?
Zero monitor manufacturing
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
There is a shotgun approach to improvements; people have little concern for improving methods.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.