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 two of key 8?
Coupled manufacturing
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Emphasize the connections between processes and full employee participation in improvement making
Operators know they must keep their machines in good condition and eliminate the three evils.


2. What are the three principles of prevention?
Video tape a person doing this so they can review what they're doing and improve.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Maintain normal conditions - early discovery of abnormalities - and prompt response.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.


3. What is takt time?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Anyone could find any file within one minute.
Helps you understand the facts as they are.
The available production time divided by the rate of customer demand


4. What is key #7?
Supervisors meet to work out time control issues
Zero monitor manufacturing
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
No one realizes that monitoring is waste - not work


5. What are the different types of motions required for performing an operation? (Type 1 motions)
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


6. What is level 3 of key 9?
Operators know they must keep their machines in good condition and eliminate the three evils.
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'.
Time it takes to make one unit
It's hard because it deals with attitudes of employees.


7. What is push production?

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8. What are the basic steps in a traditional changeover?
Emphasize the connections between processes and full employee participation in improvement making
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Hands-on activity based on the facts - not opinion.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments


9. What are the benefits of quick changeover for companies?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Double capacity and the per unit production cost is 60% of the lower capacity option.
People have learned how to make systematic improvements at each process.


10. At level three of key 6 - what is the methodology employees have been trained to use?
Manufacturing value analysis
Industrial engineering methodologies
No one realizes that monitoring is waste - not work
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments


11. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
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'.
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
Maintaining equipment


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

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13. What is key #9?
You have to communicate! Coordinate where the output is going to be stored.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Maintaining equipment
Each section does its own thing; each workplace functions independently


14. What are the 5 pillars of TPM?

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15. What is level one of key 5?
Doubling productivity - Productivity = Output / TEE
You want to equalize your work loads in terms of your lot size - one-piece flow.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


16. What are the three evils?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Manufacturing value analysis
Contamination - inadequate lubrication - misoperation
No one realizes that monitoring is waste - not work


17. What is level four of key 7?
Can be done while the machine is still processing.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
No one realizes that monitoring is waste - not work
All machines can operate during lunch without monitoring and many operators can handle two or more machines


18. What are the five components of TPM?
Factory employees begin setting up inter-process stores
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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.


19. What is the goal of motion study?
To eliminate the big 3.
Anyone could find any file within one minute.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Study the movement and motions of a worker or associate


20. What is level one of key 7?
Study the movement and motions of a worker or associate
No one realizes that monitoring is waste - not work
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
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.


21. What is corrective maintenance?
Anyone could find any file within one minute.
Zero monitor manufacturing
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.


22. What is the purpose of Cyclegraphic analysis?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Knowledge - Job security - Safety - Simplicity
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
Run the machines into the ground


23. What is the 'Six-Tenths Rule'?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Double capacity and the per unit production cost is 60% of the lower capacity option.
Factory employees begin setting up inter-process stores
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)


24. What are the steps in Shingo's changeover system?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Can be done while the machine is still processing.


25. What is level one of key 8?
Time measuring
Each section does its own thing; each workplace functions independently
Zero monitor manufacturing
All machines can operate during lunch without monitoring and many operators can handle two or more machines


26. What are the benefits of properly maintaining equipment?
Contamination - inadequate lubrication - misoperation
Coupled manufacturing
The available production time divided by the rate of customer demand
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


27. What is preventative maintenance?
No one realizes that monitoring is waste - not work
Identifying problems before they cause breakdowns.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Coupled manufacturing


28. What is level one of key 6?
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)
There is a shotgun approach to improvements; people have little concern for improving methods.
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
Contamination - inadequate lubrication - misoperation


29. Full work systems
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.
Time control and commitment
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


30. 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.
Study the movement and motions of a worker or associate
Factory employees begin setting up inter-process stores
Hands-on activity based on the facts - not opinion.


31. What is cycle time?
Time it takes to make one unit
Large scale improvement
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
Emphasize the connections between processes and full employee participation in improvement making


32. What is kaizen?
Operators know they must keep their machines in good condition and eliminate the three evils.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Continuous improvement of person and process
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance


33. What is multi-process handling?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
One operator handling several machines or processes
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.


34. What is level 2 of key 10?
People have learned how to make systematic improvements at each process.
Eliminate certain processes that produce or create waste.
Morning pep talk meetings are held everyday
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


35. What is level four of key 6?
Workers are conscientious about sticking to the work throughout the designated working areas.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
You have to communicate! Coordinate where the output is going to be stored.
Each section does its own thing; each workplace functions independently


36. What is pull production?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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'.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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


37. What is level three of key 8?
Study the flow of a product through the various operations
Factory employees begin setting up inter-process stores
Manufacturing value analysis
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)


38. 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.
The available production time divided by the rate of customer demand
Time it takes to make one unit
Morning pep talk meetings are held everyday


39. What is level three of key 6?
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.
Helps you understand the facts as they are.
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.
People have learned how to make systematic improvements at each process.


40. What is level 1 of key 9?
The customer's order starts the process
Run the machines into the ground
People have learned how to make systematic improvements at each process.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


41. What are the motions that do not perform an operation?
Industrial engineering methodologies
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Continuous improvement of person and process
Backorders create complacency.


42. What is predictive maintenance?
Determining the life expectancy of components in order to replace them at the optimum time.
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
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Helps you understand the facts as they are.


43. What is the new product introduction loop?

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44. What does kanban do?
Factory employees begin setting up inter-process stores
Everyone understands the need for PM; PM has been implemented for the most important machines.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


45. What is key 10?
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
Time control and commitment
Involving production employees in the total machine maintenance process.
Doubling productivity - Productivity = Output / TEE


46. What is an external setup element?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Can be done while the machine is still processing.
Run the machines into the ground
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


47. What is the purpose of Therblig analysis?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Helps you understand the facts as they are.
Coupled manufacturing
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


48. What is level 2 of key 9?
Prevents equipment from breaking down or malfunctioning.
Knowledge - Job security - Safety - Simplicity
Everyone understands the need for PM; PM has been implemented for the most important machines.
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 are the functions and rules of kanban?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Quick changeover technology
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
Large scale improvement


50. What is the framework for the morning meeting - the after lunch meeting - and the end-of-the-day meeting?

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