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Lean Management

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 2 of key 9?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Cycle time - work sequence - standard inventory
One operator handling several machines or processes
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

2. What are the motions that slow down Type 1 motions?
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)
Anyone could find any file within one minute.
People have learned how to make systematic improvements at each process.
Can only be done when the machine is stopped or shut down.

3. What are the five components of TPM?
Eliminate certain processes that produce or create waste.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Can be done while the machine is still processing.
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

4. What is level one of key 5?
Can be done while the machine is still processing.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Contamination - inadequate lubrication - misoperation

5. What are the three principles of prevention?
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
Preventative maintenance - Prevention maintenance - Corrective prevention
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'.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

6. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
People have learned how to make systematic improvements at each process.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

7. What is product flow charting?
Staying competitive with yesterday's products is difficult - if not impossible.
Study the flow of a product through the various operations
Preventative maintenance - Prevention maintenance - Corrective prevention
Inventory waste - Delay - Declining quality

8. What are the three evils?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Eliminate certain processes that produce or create waste.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Contamination - inadequate lubrication - misoperation

9. What is level three of key 7?
People have learned how to make systematic improvements at each process.
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
There is a shotgun approach to improvements; people have little concern for improving methods.

10. What is the purpose of Cyclegraphic analysis?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Machines work together to prevent overproduction - it stops once it meets demands.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Filming someone with a light on their finger so you can see the movements to better improve the design.

11. What are the three key technical activities in a TPM program?
Supervisors meet to work out time control issues
Preventative maintenance - Prevention maintenance - Corrective prevention
Can be done while the machine is still processing.
To eliminate the big 3.

12. 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.
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
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.
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

13. What appears to be the primary metric in key 6?
One operator handling several machines or processes
Time measuring
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

14. What is key #6?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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.
Manufacturing value analysis
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

15. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Time it takes to make one unit
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Morning pep talk meetings are held everyday

16. What is autonomation (Jidoka)?
Filming someone with a light on their finger so you can see the movements to better improve the design.
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.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

17. What are the steps in Shingo's changeover system?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
People have learned how to make systematic improvements at each process.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

18. What are the functions and rules of kanban?
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
Zero monitor manufacturing
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

19. At level three of key 6 - what is the methodology employees have been trained to use?
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.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Executives do not understand the high rate of return linked to integrated improvement.
Industrial engineering methodologies

20. What is key #5?
To eliminate the big 3.
Quick changeover technology
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
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

21. What is level 3 of key 10?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Supervisors meet to work out time control issues
You have to communicate! Coordinate where the output is going to be stored.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

22. What is key #8?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Preventative maintenance - Prevention maintenance - Corrective prevention
Coupled manufacturing
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

23. What is pull production?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Filming someone with a light on their finger so you can see the movements to better improve the design.
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
Study the movement and motions of a worker or associate

24. What are the 5 pillars of TPM?

25. What is cycle time?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Factory employees begin setting up inter-process stores
Time it takes to make one unit

26. What is the make/ship loop?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Backorders create complacency.
Double capacity and the per unit production cost is 60% of the lower capacity option.
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

27. What is the purpose of Therblig analysis?
You have to communicate! Coordinate where the output is going to be stored.
Each section does its own thing; each workplace functions independently
Helps you understand the facts as they are.
Double capacity and the per unit production cost is 60% of the lower capacity option.

28. What is kaizen?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Continuous improvement of person and process
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

29. What is level three of key 8?
Factory employees begin setting up inter-process stores
Backorders create complacency.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

30. What is key 10?
It's hard because it deals with attitudes of employees.
Staying competitive with yesterday's products is difficult - if not impossible.
Time control and commitment
The available production time divided by the rate of customer demand

31. What is key #9?
Each section does its own thing; each workplace functions independently
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
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Maintaining equipment

32. What is the goal of motion study?
To eliminate the big 3.
Large scale improvement
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Everyone understands the need for PM; PM has been implemented for the most important machines.

33. What is the purpose of Chronocyclegraphic analysis?
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.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
People have learned how to make systematic improvements at each process.
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

34. What is level 5 of key 10?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Study the flow of a product through the various operations
Can only be done when the machine is stopped or shut down.

35. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
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
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
Inventory waste - Delay - Declining quality

36. What is predictive maintenance?
Determining the life expectancy of components in order to replace them at the optimum time.
There is a shotgun approach to improvements; people have little concern for improving methods.
Cycle time - work sequence - standard inventory
Time it takes to make one unit

37. What is the warning Kobayashi gives with respect to Key 10?

38. What is the purpose of video analysis?

39. What is the value of TPM?
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.
Maintaining equipment
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Hands-on activity based on the facts - not opinion.

40. What are the basic steps in a traditional changeover?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Work and break times are left to the workers' discretion
Quick changeover technology
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

41. What does TPM do?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Can only be done when the machine is stopped or shut down.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Prevents equipment from breaking down or malfunctioning.

42. What is Industrial Engineering?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Machines work together to prevent overproduction - it stops once it meets demands.
Cycle time - work sequence - standard inventory
Hands-on activity based on the facts - not opinion.

43. What is level 5 of key 9?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous 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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Time measuring

44. What is preventative maintenance?
Identifying problems before they cause breakdowns.
Workers are conscientious about sticking to the work throughout the designated working areas.
One operator handling several machines or processes
Factory employees begin setting up inter-process stores

45. What is level 1 of key 9?
Run the machines into the ground
Work and break times are left to the workers' discretion
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Time measuring

46. What does manufacturing value analysis do?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
No one realizes that monitoring is waste - not work

47. What is full work system?
Staying competitive with yesterday's products is difficult - if not impossible.
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
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Machines work together to prevent overproduction - it stops once it meets demands.

48. What are the different types of motions required for performing an operation? (Type 1 motions)
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Machines work together to prevent overproduction - it stops once it meets demands.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

49. What is takt time?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
The available production time divided by the rate of customer demand
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.
Zero monitor manufacturing

50. What is level five of key 8?
Executives do not understand the high rate of return linked to integrated improvement.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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
Morning pep talk meetings are held everyday