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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.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

2. What are the motions that slow down Type 1 motions?
Zero monitor manufacturing
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)
Manufacturing value analysis
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

3. 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.
Determining the life expectancy of components in order to replace them at the optimum time.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Factory employees begin setting up inter-process stores

4. What is pull production?
Anyone could find any file within one minute.
Can be done while the machine is still processing.
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

5. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Large scale improvement
You want to equalize your work loads in terms of your lot size - one-piece flow.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

6. What are the three evils?
Contamination - inadequate lubrication - misoperation
Morning pep talk meetings are held everyday
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.
Factory employees begin setting up inter-process stores

7. What has to be done to get to level two of key 8?
Continuous improvement of person and process
One operator handling several machines or processes
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
You have to communicate! Coordinate where the output is going to be stored.

8. What does TPM do?
Hands-on activity based on the facts - not opinion.
Prevents equipment from breaking down or malfunctioning.
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)
Doubling productivity - Productivity = Output / TEE

9. What is level four of key 8?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
You have to communicate! Coordinate where the output is going to be stored.
People have learned how to make systematic improvements at each process.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

10. What is kaizen?
Preventative maintenance - Prevention maintenance - Corrective prevention
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Continuous improvement of person and process
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

11. What is kaikaku?
One operator handling several machines or processes
Quick changeover technology
Zero monitor manufacturing
Large scale improvement

12. What appears to be the primary metric in 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.
Eliminate certain processes that produce or create waste.
Time measuring
Everyone recognizes that monitoring is waste

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

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14. What is autonomation (Jidoka)?
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'.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Identifying problems before they cause breakdowns.
Study the flow of a product through the various operations

15. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Everyone recognizes that monitoring is waste
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

16. What are the steps in Shingo's changeover system?
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.
Doubling productivity - Productivity = Output / TEE
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Anyone could find any file within one minute.

17. What is key 10?
Run the machines into the ground
Time control and commitment
Can be done while the machine is still processing.
It's hard because it deals with attitudes of employees.

18. What is the 'Six-Tenths Rule'?
There is a shotgun approach to improvements; people have little concern for improving methods.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Double capacity and the per unit production cost is 60% of the lower capacity option.

19. What does kanban do?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Everyone recognizes that monitoring is waste
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Workers are conscientious about sticking to the work throughout the designated working areas.

20. What is multi-process handling?
Quick changeover studies begin; some employees are learning how to implement single changeover.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
One operator handling several machines or processes

21. What is the purpose of Cyclegraphic analysis?
Time it takes to make one unit
Study the flow of a product through the various operations
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 so you can see the movements to better improve the design.

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

23. What is prevention maintenance?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Involving production employees in the total machine maintenance process.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

24. 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
The available production time divided by the rate of customer demand
Anyone could find any file within one minute.
You want to equalize your work loads in terms of your lot size - one-piece flow.

25. What is level two of key 5?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Industrial engineering methodologies
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Quick changeover studies begin; some employees are learning how to implement single changeover.

26. What is level three of key 6?
People have learned how to make systematic improvements at each process.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Knowledge - Job security - Safety - Simplicity
Inventory waste - Delay - Declining quality

27. What are the process improvement steps?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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
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

28. What is level four of key 5?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Time measuring
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.
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 two of key 6?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Can only be done when the machine is stopped or shut down.
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'.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

30. What are the motions that do not perform an operation?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
One operator handling several machines or processes

31. What is corrective maintenance?
Hands-on activity based on the facts - not opinion.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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.
Time it takes to make one unit

32. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Doubling productivity - Productivity = Output / TEE
Cycle time - work sequence - standard inventory
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

33. What is level two of key 7?
Everyone recognizes that monitoring is waste
Identifying problems before they cause breakdowns.
Operators know they must keep their machines in good condition and eliminate the three evils.
Hands-on activity based on the facts - not opinion.

34. What is level one of key 8?
Each section does its own thing; each workplace functions independently
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.
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

35. What did Frank Gilbreth do?
Time control and commitment
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.
Made the basic elements of human motion (therbligs)
You want to equalize your work loads in terms of your lot size - one-piece flow.

36. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

37. What is level 5 of key 9?
People have learned how to make systematic improvements at each process.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
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.
Knowledge - Job security - Safety - Simplicity

38. What are the benefits of quick changeover for companies?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Determining the life expectancy of components in order to replace them at the optimum time.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

39. What is level one of key 6?
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.
There is a shotgun approach to improvements; people have little concern for improving methods.
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)
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

40. What are the benefits of properly maintaining equipment?
Zero monitor manufacturing
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.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Helps you understand the facts as they are.

41. What is 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.
Involving production employees in the total machine maintenance process.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Run the machines into the ground

42. What is level five of key 6?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Industrial engineering methodologies
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 control and commitment

43. What are the benefits of quick changeover for associates?
Backorders create complacency.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Knowledge - Job security - Safety - Simplicity
Maintain normal conditions - early discovery of abnormalities - and prompt response.

44. What is level 2 of key 10?
Made the basic elements of human motion (therbligs)
Morning pep talk meetings are held everyday
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

45. What is preventative maintenance?
Identifying problems before they cause breakdowns.
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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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.

46. What is level four of key 6?
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'.
One operator handling several machines or processes
Cycle time - work sequence - standard inventory
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

47. What is the trouble with large-lot production?
Morning pep talk meetings are held everyday
Inventory waste - Delay - Declining quality
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'.
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.

48. What is level 1 of key 9?
Run the machines into the ground
Manufacturing value analysis
Video tape a person doing this so they can review what they're doing and improve.
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.

49. What are the three pillars of lean systems?
The customer's order starts the process
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Determining the life expectancy of components in order to replace them at the optimum time.

50. What are the five components of TPM?
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.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance