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Lean Management

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Answer 50 questions in 15 minutes.
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Match each statement with the correct term.
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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 five of key 8?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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.
Maintaining equipment

2. 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.
Anyone could find any file within one minute.
Quick changeover technology
Maintaining equipment

3. What is the goal of motion study?
To eliminate the big 3.
Prevents equipment from breaking down or malfunctioning.
Everyone understands the need for PM; PM has been implemented for the most important machines.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

4. What is product flow charting?
Continuous improvement of person and process
There is a shotgun approach to improvements; people have little concern for improving methods.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Study the flow of a product through the various operations

5. What are the benefits of quick changeover for companies?
Study the flow of a product through the various operations
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
Helps you understand the facts as they are.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

6. What are the basic steps in a traditional changeover?
Emphasize the connections between processes and full employee participation in improvement making
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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.

7. What is level 1 of key 10?

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8. What are the flowcharting rules of construction?
Work and break times are left to the workers' discretion
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

9. What does TPM do?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Knowledge - Job security - Safety - Simplicity
Prevents equipment from breaking down or malfunctioning.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

10. What are the three evils?
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.
Contamination - inadequate lubrication - misoperation
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

11. What is level one of key 5?
Cycle time - work sequence - standard inventory
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
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.

12. What is level 3 of key 10?
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.
Supervisors meet to work out time control issues
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.

13. What are the three principles of prevention?
Eliminate certain processes that produce or create waste.
Staying competitive with yesterday's products is difficult - if not impossible.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Quick changeover studies begin; some employees are learning how to implement single changeover.

14. What is multi-process handling?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
One operator handling several machines or processes
The available production time divided by the rate of customer demand
Large scale improvement

15. At level three of key 6 - what is the methodology employees have been trained to use?
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.
Study the movement and motions of a worker or associate

16. What is preventive maintenance?
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)
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Made the basic elements of human motion (therbligs)
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

17. What is level four of key 7?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

18. What is level one of key 7?
No one realizes that monitoring is waste - not work
Work and break times are left to the workers' discretion
Eliminate certain processes that produce or create waste.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

19. What is preventative maintenance?
Run the machines into the ground
Time control and commitment
Identifying problems before they cause breakdowns.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

20. What is level one of key 8?
Each section does its own thing; each workplace functions independently
Knowledge - Job security - Safety - Simplicity
Hands-on activity based on the facts - not opinion.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

21. What is level five of key 7?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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
Inventory waste - Delay - Declining quality

22. What are the motions that do not perform an operation?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Zero monitor manufacturing
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

23. What is level four of key 8?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Hands-on activity based on the facts - not opinion.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

24. What is takt time?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
People have learned how to make systematic improvements at each process.
Backorders create complacency.
The available production time divided by the rate of customer demand

25. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
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
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

26. What is level 5 of key 10?
Work and break times are left to the workers' discretion
Everyone recognizes that monitoring is waste
Knowledge - Job security - Safety - Simplicity
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

27. What are the three key technical activities in a TPM program?
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
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Quick changeover technology

28. What is key 10?
Continuous improvement of person and process
Time control and commitment
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)
Knowledge - Job security - Safety - Simplicity

29. What is level three of key 5?
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.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Manufacturing value analysis
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

30. What is level five of key 6?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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.
Time control and commitment

31. What is level three of key 8?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Factory employees begin setting up inter-process stores
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Supervisors meet to work out time control issues

32. What is key #7?
Coupled manufacturing
Zero monitor 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.
Emphasize the connections between processes and full employee participation in improvement making

33. What is level three of key 6?
Prevents equipment from breaking down or malfunctioning.
Maintaining equipment
People have learned how to make systematic improvements at each process.
Operators know they must keep their machines in good condition and eliminate the three evils.

34. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
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.
Eliminate certain processes that produce or create waste.
You want to equalize your work loads in terms of your lot size - one-piece flow.

35. What does manufacturing value analysis do?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Zero monitor manufacturing
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

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

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37. What is the main goal of MVA?
No one realizes that monitoring is waste - not work
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Backorders create complacency.
Doubling productivity - Productivity = Output / TEE

38. What are the different types of motions required for performing an operation? (Type 1 motions)
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Time measuring
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

39. What are the 6 Big Losses of TPM?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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
Eliminate certain processes that produce or create waste.

40. What is pull production?
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
Anyone could find any file within one minute.
Run the machines into the ground
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

41. What did Frank Gilbreth do?
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.
Can only be done when the machine is stopped or shut down.
Run the machines into the ground
Made the basic elements of human motion (therbligs)

42. What is kaikaku?
Morning pep talk meetings are held everyday
People have learned how to make systematic improvements at each process.
Large scale improvement
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

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

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44. What is key #8?
Industrial engineering methodologies
Coupled manufacturing
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

45. What appears to be the primary metric in key 6?
Each section does its own thing; each workplace functions independently
Time measuring
You have to communicate! Coordinate where the output is going to be stored.
Hands-on activity based on the facts - not opinion.

46. What is the purpose of Chronocyclegraphic analysis?
Identifying problems before they cause breakdowns.
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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.

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

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48. What are the motions that slow down Type 1 motions?
Time measuring
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)
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Industrial engineering methodologies

49. What is the strategic business development loop?
Executives do not understand the high rate of return linked to integrated improvement.
Coupled manufacturing
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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.

50. What is cycle time?
Time it takes to make one unit
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
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
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

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