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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 are the flowcharting rules of construction?
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
Continuous improvement of person and process
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

2. What is level 2 of key 9?
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.
It's hard because it deals with attitudes of employees.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

3. What is level three of key 7?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Involving production employees in the total machine maintenance process.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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

4. What is level five of key 7?
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.
Large scale improvement
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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)

5. What is level 4 of key 9?
Study the flow of a product through the various operations
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

6. What are the benefits of properly maintaining equipment?
Zero monitor manufacturing
Each section does its own thing; each workplace functions independently
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 breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

7. What is level 3 of key 10?
Supervisors meet to work out time control issues
Factory employees begin setting up inter-process stores
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.

8. What is kaizen?
Continuous improvement of person and process
Emphasize the connections between processes and full employee participation in improvement making
Prevents equipment from breaking down or malfunctioning.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

9. What is push production?

10. What are the steps in Shingo's changeover system?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Zero monitor manufacturing
You want to equalize your work loads in terms of your lot size - one-piece flow.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

11. What is level three of key 8?
Cycle time - work sequence - standard inventory
Coupled manufacturing
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.
Factory employees begin setting up inter-process stores

12. What are the three key technical activities in a TPM program?
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
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'.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Preventative maintenance - Prevention maintenance - Corrective prevention

13. What is the trouble with large-lot production?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Study the flow of a product through the various operations
Inventory waste - Delay - Declining quality

14. At level three of key 6 - what is the methodology employees have been trained to use?
Inventory waste - Delay - Declining quality
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Industrial engineering methodologies
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

15. What is production leveling?
Workers are conscientious about sticking to the work throughout the designated working areas.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Time control and commitment

16. What is level four of key 6?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Run the machines into the ground

17. What is an external setup element?
Hands-on activity based on the facts - not opinion.
Can be done while the machine is still processing.
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.
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.

18. What is level three 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.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
People have learned how to make systematic improvements at each process.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation

19. What did Frank Gilbreth do?
Identifying problems before they cause breakdowns.
Made the basic elements of human motion (therbligs)
Morning pep talk meetings are held everyday
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

20. What is the purpose of Therblig analysis?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Operators know they must keep their machines in good condition and eliminate the three evils.
Helps you understand the facts as they are.
Knowledge - Job security - Safety - Simplicity

21. What is key 10?
Time control and commitment
Run the machines into the ground
Coupled manufacturing
Filming someone with a light on their finger so you can see the movements to better improve the design.

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

23. What is the make/ship loop?
Continuous improvement of person and process
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.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Backorders create complacency.

24. What are the five components of TPM?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Work and break times are left to the workers' discretion
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.

25. What is multi-process handling?
One operator handling several machines or processes
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Inventory waste - Delay - Declining quality
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.

26. What is level five of key 6?
Cycle time - work sequence - standard inventory
Coupled manufacturing
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Helps you understand the facts as they are.

27. What has to be done to get to level two of key 8?
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
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
Determining the life expectancy of components in order to replace them at the optimum time.
You have to communicate! Coordinate where the output is going to be stored.

28. What is cycle time?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Time it takes to make one unit
Cycle time - work sequence - standard inventory

29. What are the three evils?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Time control and commitment
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Contamination - inadequate lubrication - misoperation

30. What is the goal of motion study?
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
To eliminate the big 3.
Identifying problems before they cause breakdowns.
Emphasize the connections between processes and full employee participation in improvement making

31. What is level one of key 7?
No one realizes that monitoring is waste - not work
Helps you understand the facts as they are.
Time control and commitment
The customer's order starts the process

32. What is corrective maintenance?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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)
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

33. What are the motions that slow down Type 1 motions?
Eliminate certain processes that produce or create waste.
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)
You want to equalize your work loads in terms of your lot size - one-piece flow.
Executives do not understand the high rate of return linked to integrated improvement.

34. What appears to be the primary metric in key 6?
Quick changeover technology
Coupled manufacturing
Time measuring
Study the movement and motions of a worker or associate

35. What is prevention maintenance?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Eliminate certain processes that produce or create waste.
Video tape a person doing this so they can review what they're doing and improve.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

36. What are the first two steps in setting up a maintenance management system?

37. What is autonomation (Jidoka)?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
People have learned how to make systematic improvements at each process.
Large scale improvement

38. What is the purpose of operator flow charting?
Eliminate certain processes that produce or create waste.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Can only be done when the machine is stopped or shut down.

39. What is level four of key 8?
Staying competitive with yesterday's products is difficult - if not impossible.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Time it takes to make one unit
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

40. What is level two of key 8?
Large scale improvement
Everyone understands the need for PM; PM has been implemented for the most important machines.
Emphasize the connections between processes and full employee participation in improvement making
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'.

41. What are the 5 pillars of TPM?

42. What is the value of TPM?
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
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.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

43. What is the new product introduction loop?

44. What is takt time?
Preventative maintenance - Prevention maintenance - Corrective prevention
The available production time divided by the rate of customer demand
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

45. What is level four of key 7?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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
Maintain normal conditions - early discovery of abnormalities - and prompt response.

46. What are the three pillars of lean systems?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Zero monitor manufacturing
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

47. What is level 4 of key 10?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Workers are conscientious about sticking to the work throughout the designated working areas.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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

48. What is level 1 of key 10?

49. What is the 'Six-Tenths Rule'?
Operators know they must keep their machines in good condition and eliminate the three evils.
Work and break times are left to the workers' discretion
Continuous improvement of person and process
Double capacity and the per unit production cost is 60% of the lower capacity option.

50. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
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
Industrial engineering methodologies