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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 autonomous maintenance?
Involving production employees in the total machine maintenance process.
Staying competitive with yesterday's products is difficult - if not impossible.
Zero monitor manufacturing
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

2. What does kanban do?
No one realizes that monitoring is waste - not work
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Determining the life expectancy of components in order to replace them at the optimum time.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

3. What is level 1 of key 10?

4. What is level one of key 6?
Staying competitive with yesterday's products is difficult - if not impossible.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
One operator handling several machines or processes
There is a shotgun approach to improvements; people have little concern for improving methods.

5. What is multi-process handling?
Time control and commitment
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Emphasize the connections between processes and full employee participation in improvement making
One operator handling several machines or processes

6. What is level two of key 8?
Backorders create complacency.
Emphasize the connections between processes and full employee participation in improvement making
Run the machines into the ground
You want to equalize your work loads in terms of your lot size - one-piece flow.

7. What are the benefits of quick changeover for associates?
Each section does its own thing; each workplace functions independently
Knowledge - Job security - Safety - Simplicity
Video tape a person doing this so they can review what they're doing and improve.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

8. What is the goal of motion study?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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.
To eliminate the big 3.
Work and break times are left to the workers' discretion

9. What is level five 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)
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Doubling productivity - Productivity = Output / TEE

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

11. What is level five of key 7?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
There is a shotgun approach to improvements; people have little concern for improving methods.
Work and break times are left to the workers' discretion
Identifying problems before they cause breakdowns.

12. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
It's hard because it deals with attitudes of employees.
Study the flow of a product through the various operations
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.

13. What are the steps in Shingo's changeover system?
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
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Emphasize the connections between processes and full employee participation in improvement making
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

14. What is key 10?
Double capacity and the per unit production cost is 60% of the lower capacity option.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Time control and commitment
Maintaining equipment

15. What is operator flow charting?
Zero monitor manufacturing
Study the movement and motions of a worker or associate
Can only be done when the machine is stopped or shut down.
Emphasize the connections between processes and full employee participation in improvement making

16. What is kaizen?
Continuous improvement of person and process
To eliminate the big 3.
Factory employees begin setting up inter-process stores
Helps you understand the facts as they are.

17. What is level one of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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)
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

18. What is the new product introduction loop?

19. What is cycle time?
Industrial engineering methodologies
Preventative maintenance - Prevention maintenance - Corrective prevention
Everyone recognizes that monitoring is waste
Time it takes to make one unit

20. What is an external setup element?
Can be done while the machine is still processing.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Machines work together to prevent overproduction - it stops once it meets demands.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

21. What is corrective maintenance?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Eliminate certain processes that produce or create waste.
Determining the life expectancy of components in order to replace them at the optimum time.

22. What is the make/ship loop?
Time it takes to make one unit
Double capacity and the per unit production cost is 60% of the lower capacity option.
Backorders create complacency.
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.

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

24. What is autonomation (Jidoka)?
Determining the life expectancy of components in order to replace them at the optimum time.
Time control and commitment
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

25. What is key #8?
Preventative maintenance - Prevention maintenance - Corrective prevention
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Coupled manufacturing
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

26. What is level four of key 6?
Knowledge - Job security - Safety - Simplicity
One operator handling several machines or processes
Helps you understand the facts as they are.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

27. Full work systems
Staying competitive with yesterday's products is difficult - if not impossible.
Emphasize the connections between processes and full employee participation in improvement making
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
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

28. What is level one of key 7?
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
Can only be done when the machine is stopped or shut down.
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
No one realizes that monitoring is waste - not work

29. What is key #7?
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
Zero monitor manufacturing
Can be done while the machine is still processing.
Video tape a person doing this so they can review what they're doing and improve.

30. What are the three evils?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Contamination - inadequate lubrication - misoperation
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)
Maintaining equipment

31. What is kaikaku?
Large scale improvement
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

32. What is level 2 of key 9?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Hands-on activity based on the facts - not opinion.
Everyone understands the need for PM; PM has been implemented for the most important machines.

33. What is key #6?
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
Identifying problems before they cause breakdowns.
Manufacturing value analysis
The available production time divided by the rate of customer demand

34. What is the value of TPM?
Machines work together to prevent overproduction - it stops once it meets demands.
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.
Can be done while the machine is still processing.
Can only be done when the machine is stopped or shut down.

35. 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)
Each section does its own thing; each workplace functions independently
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
You want to equalize your work loads in terms of your lot size - one-piece flow.

36. What is level 4 of key 10?
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
Workers are conscientious about sticking to the work throughout the designated working areas.
Double capacity and the per unit production cost is 60% of the lower capacity option.
It's hard because it deals with attitudes of employees.

37. What are the benefits of properly maintaining equipment?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
You have to communicate! Coordinate where the output is going to be stored.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

38. What is the purpose of Therblig analysis?
Video tape a person doing this so they can review what they're doing and improve.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Zero monitor manufacturing
Helps you understand the facts as they are.

39. What is prevention maintenance?
Knowledge - Job security - Safety - Simplicity
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Contamination - inadequate lubrication - misoperation
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

40. What is level four of key 5?
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)
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Each section does its own thing; each workplace functions independently
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

41. What has to be done to get to level two of key 8?
You have to communicate! Coordinate where the output is going to be stored.
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
People have learned how to make systematic improvements at each process.

42. What is the purpose of flowcharting?
Coupled manufacturing
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
You have to communicate! Coordinate where the output is going to be stored.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

43. What are the three pillars of lean systems?
Work and break times are left to the workers' discretion
Industrial engineering methodologies
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'.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

44. What are the five components of TPM?
Quick changeover technology
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
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

45. What is the purpose of Chronocyclegraphic analysis?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Prevents equipment from breaking down or malfunctioning.
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.
Morning pep talk meetings are held everyday

46. What is production leveling?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Double capacity and the per unit production cost is 60% of the lower capacity option.
You want to equalize your work loads in terms of your lot size - one-piece flow.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

47. What is level five of key 5?
Can only be done when the machine is stopped or shut down.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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
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

48. What is level two of key 7?
Everyone recognizes that monitoring is waste
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Hands-on activity based on the facts - not opinion.
Executives do not understand the high rate of return linked to integrated improvement.

49. What is level three of key 7?
Operators know they must keep their machines in good condition and eliminate the three evils.
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
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.

50. What is an internal setup element?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Contamination - inadequate lubrication - misoperation
It's hard because it deals with attitudes of employees.
Can only be done when the machine is stopped or shut down.