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 first two steps in setting up a maintenance management system?

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2. What are the three elements of the standard work sheet?
Cycle time - work sequence - standard inventory
Morning pep talk meetings are held everyday
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


3. What are the different types of motions required for performing an operation? (Type 1 motions)
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.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Workers are conscientious about sticking to the work throughout the designated working areas.
Doubling productivity - Productivity = Output / TEE


4. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Made the basic elements of human motion (therbligs)
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
People have learned how to make systematic improvements at each process.


5. What is autonomation (Jidoka)?
Made the basic elements of human motion (therbligs)
To eliminate the big 3.
Hands-on activity based on the facts - not opinion.
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 are the three evils?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Cycle time - work sequence - standard inventory
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Contamination - inadequate lubrication - misoperation


7. What is level three of key 7?
Coupled manufacturing
Helps you understand the facts as they are.
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


8. What is level 4 of key 10?
Workers are conscientious about sticking to the work throughout the designated working areas.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Eliminate certain processes that produce or create waste.
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.


9. What is the purpose of video analysis?

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10. What are the three principles of prevention?
Supervisors meet to work out time control issues
Manufacturing value analysis
Maintain normal conditions - early discovery of abnormalities - and prompt response.
The available production time divided by the rate of customer demand


11. What is push production?

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12. What is takt time?
The available production time divided by the rate of customer demand
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
People have learned how to make systematic improvements at each process.
No one realizes that monitoring is waste - not work


13. What is multi-process handling?
Hands-on activity based on the facts - not opinion.
You have to communicate! Coordinate where the output is going to be stored.
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.
One operator handling several machines or processes


14. What is cycle time?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Time it takes to make one unit
Supervisors meet to work out time control issues
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign


15. What is kaizen?
Continuous improvement of person and process
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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.
Study the movement and motions of a worker or associate


16. What is key 10?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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.
Time control and commitment
Executives do not understand the high rate of return linked to integrated improvement.


17. What is single file retrieval?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Anyone could find any file within one minute.
Work and break times are left to the workers' discretion
Maintaining equipment


18. What is level one of key 6?
The available production time divided by the rate of customer demand
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Manufacturing value analysis
There is a shotgun approach to improvements; people have little concern for improving methods.


19. What does manufacturing value analysis do?
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
Preventative maintenance - Prevention maintenance - Corrective prevention
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Factory employees begin setting up inter-process stores


20. What is the 'Six-Tenths Rule'?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Morning pep talk meetings are held everyday
Double capacity and the per unit production cost is 60% of the lower capacity option.


21. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
Staying competitive with yesterday's products is difficult - if not impossible.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.


22. What is level 3 of key 10?
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.
Supervisors meet to work out time control issues
No one realizes that monitoring is waste - not work


23. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Supervisors meet to work out time control issues
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


24. What is level two of key 5?
Time control and commitment
Quick changeover studies begin; some employees are learning how to implement single changeover.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


25. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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
Backorders create complacency.
Work and break times are left to the workers' discretion


26. What are the motions that slow down Type 1 motions?
Time measuring
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
You want to equalize your work loads in terms of your lot size - one-piece flow.
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)


27. 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.
Can only be done when the machine is stopped or shut down.
Contamination - inadequate lubrication - misoperation
Knowledge - Job security - Safety - Simplicity


28. What is predictive maintenance?
Work and break times are left to the workers' discretion
Eliminate certain processes that produce or create waste.
Determining the life expectancy of components in order to replace them at the optimum time.
The customer's order starts the process


29. What is level two of 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
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Video tape a person doing this so they can review what they're doing and improve.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)


30. What is product flow charting?
Contamination - inadequate lubrication - misoperation
Study the flow of a product through the various operations
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.
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


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

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32. What is level 2 of key 10?
Morning pep talk meetings are held everyday
Eliminate certain processes that produce or create waste.
Made the basic elements of human motion (therbligs)
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


33. 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
Work and break times are left to the workers' discretion
Coupled manufacturing
Identifying problems before they cause breakdowns.


34. What is an external setup element?
Maintaining equipment
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
Can be done while the machine is still processing.
Operators know they must keep their machines in good condition and eliminate the three evils.


35. What does TPM do?
Workers are conscientious about sticking to the work throughout the designated working areas.
Prevents equipment from breaking down or malfunctioning.
Work and break times are left to the workers' discretion
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


36. What are the benefits of quick changeover for associates?
Everyone recognizes that monitoring is waste
Knowledge - Job security - Safety - Simplicity
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Hands-on activity based on the facts - not opinion.


37. What is the new product introduction loop?

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38. What is the purpose of Therblig analysis?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Morning pep talk meetings are held everyday
Quick changeover technology
Helps you understand the facts as they are.


39. What is level five of key 7?
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
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Industrial engineering methodologies


40. What are the process improvement steps?
Study the movement and motions of a worker or associate
Video tape a person doing this so they can review what they're doing and improve.
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


41. What is prevention maintenance?
Made the basic elements of human motion (therbligs)
Supervisors meet to work out time control issues
Run the machines into the ground
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


42. What is the purpose of flowcharting?
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.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


43. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Machines work together to prevent overproduction - it stops once it meets demands.
One operator handling several machines or processes
Prevents equipment from breaking down or malfunctioning.


44. 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.
You have to communicate! Coordinate where the output is going to be stored.
Eliminate certain processes that produce or create waste.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


45. What is level three of key 8?
Factory employees begin setting up inter-process stores
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
Backorders create complacency.
Emphasize the connections between processes and full employee participation in improvement making


46. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Operators know they must keep their machines in good condition and eliminate the three evils.
To eliminate the big 3.
Zero monitor manufacturing


47. What are the benefits of properly maintaining equipment?
Machines work together to prevent overproduction - it stops once it meets demands.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Morning pep talk meetings are held everyday


48. What is the main goal of MVA?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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
Doubling productivity - Productivity = Output / TEE
Filming someone with a light on their finger so you can see the movements to better improve the design.


49. What has to be done to get to level two of key 8?
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
Industrial engineering methodologies
Run the machines into the ground
You have to communicate! Coordinate where the output is going to be stored.


50. What is preventative 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.
Identifying problems before they cause breakdowns.
Can be done while the machine is still processing.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.