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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 autonomation (Jidoka)?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Preventative maintenance - Prevention maintenance - Corrective prevention
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

2. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Study the movement and motions of a worker or associate
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Double capacity and the per unit production cost is 60% of the lower capacity option.

3. What is level 2 of key 10?
Each section does its own thing; each workplace functions independently
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Morning pep talk meetings are held everyday
Work and break times are left to the workers' discretion

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

5. What is key #7?
Zero monitor manufacturing
Factory employees begin setting up inter-process stores
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'.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

6. What appears to be the primary metric in key 6?
Helps you understand the facts as they are.
Can only be done when the machine is stopped or shut down.
Time measuring
Manufacturing value analysis

7. What is level one of key 8?
Cycle time - work sequence - standard inventory
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
Each section does its own thing; each workplace functions independently
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

8. What is operator flow charting?
Study the movement and motions of a worker or associate
The available production time divided by the rate of customer demand
Continuous improvement of person and process
It's hard because it deals with attitudes of employees.

9. At level three of key 6 - what is the methodology employees have been trained to use?
Video tape a person doing this so they can review what they're doing and improve.
Supervisors meet to work out time control issues
Industrial engineering methodologies
Executives do not understand the high rate of return linked to integrated improvement.

10. What is takt time?
The customer's order starts the process
Hands-on activity based on the facts - not opinion.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
The available production time divided by the rate of customer demand

11. What are the steps in Shingo's changeover system?
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
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

12. What is level four of key 6?
Manufacturing value analysis
Morning pep talk meetings are held everyday
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

13. What is multi-process handling?
People have learned how to make systematic improvements at each process.
Made the basic elements of human motion (therbligs)
One operator handling several machines or processes
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

14. What are the basic steps in a traditional changeover?
Cycle time - work sequence - standard inventory
Filming someone with a light on their finger so you can see the movements to better improve the design.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

15. What is an external setup element?
Time it takes to make one unit
Made the basic elements of human motion (therbligs)
Can be done while the machine is still processing.
Determining the life expectancy of components in order to replace them at the optimum time.

16. What is single file retrieval?
Video tape a person doing this so they can review what they're doing and improve.
Anyone could find any file within one minute.
Executives do not understand the high rate of return linked to integrated improvement.
Study the flow of a product through the various operations

17. What is an internal setup element?
You have to communicate! Coordinate where the output is going to be stored.
Run the machines into the ground
Everyone understands the need for PM; PM has been implemented for the most important machines.
Can only be done when the machine is stopped or shut down.

18. What is preventative maintenance?
Identifying problems before they cause breakdowns.
The customer's order starts the process
Factory employees begin setting up inter-process stores
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

19. What is kaikaku?
Factory employees begin setting up inter-process stores
Large scale improvement
Workers are conscientious about sticking to the work throughout the designated working areas.
Study the flow of a product through the various operations

20. What is level 4 of key 10?
The available production time divided by the rate of customer demand
Made the basic elements of human motion (therbligs)
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.

21. 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.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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

22. What is the make/ship loop?
Backorders create complacency.
Determining the life expectancy of components in order to replace them at the optimum time.
Work and break times are left to the workers' discretion
The available production time divided by the rate of customer demand

23. What are the motions that do not perform an operation?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Everyone understands the need for PM; PM has been implemented for the most important machines.

24. What are the three evils?
Contamination - inadequate lubrication - misoperation
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Maintaining equipment

25. What is preventive maintenance?
Manufacturing value analysis
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'.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Made the basic elements of human motion (therbligs)

26. What is kaizen?
To eliminate the big 3.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Continuous improvement of person and process

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

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28. What does manufacturing value analysis do?
Manufacturing value analysis
Zero monitor manufacturing
Operators know they must keep their machines in good condition and eliminate the three evils.
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

29. What does TPM do?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Prevents equipment from breaking down or malfunctioning.
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.

30. What is level five of key 5?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Operators know they must keep their machines in good condition and eliminate the three evils.

31. What is level one of key 6?
Machines work together to prevent overproduction - it stops once it meets demands.
There is a shotgun approach to improvements; people have little concern for improving methods.
Can only be done when the machine is stopped or shut down.
Maintaining equipment

32. What does kanban do?
Time it takes to make one unit
People have learned how to make systematic improvements at each process.
Emphasize the connections between processes and full employee participation in improvement making
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

33. What is the trouble with large-lot production?
Video tape a person doing this so they can review what they're doing and improve.
Inventory waste - Delay - Declining quality
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Identifying problems before they cause breakdowns.

34. What is full work system?
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 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
Machines work together to prevent overproduction - it stops once it meets demands.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.

35. What is level three of key 5?
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
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands the need for PM; PM has been implemented for the most important machines.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

36. What is level 1 of key 10?

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37. What is Industrial Engineering?
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.
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 available production time divided by the rate of customer demand
Hands-on activity based on the facts - not opinion.

38. What is level 4 of key 9?
Knowledge - Job security - Safety - Simplicity
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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 breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

39. What is the purpose of video analysis?

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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
Determining the life expectancy of components in order to replace them at the optimum time.
Can be done while the machine is still processing.
One operator handling several machines or processes

41. What did Frank Gilbreth do?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Eliminate certain processes that produce or create waste.
Made the basic elements of human motion (therbligs)
Backorders create complacency.

42. What is level 3 of key 9?
Manufacturing value analysis
Contamination - inadequate lubrication - misoperation
Operators know they must keep their machines in good condition and eliminate the three evils.
Double capacity and the per unit production cost is 60% of the lower capacity option.

43. What is prevention maintenance?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Continuous improvement of person and process
Made the basic elements of human motion (therbligs)

44. What is the purpose of operator flow charting?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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
Eliminate certain processes that produce or create waste.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

45. What is push production?

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46. What is key #9?
Maintaining equipment
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Prevents equipment from breaking down or malfunctioning.
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

47. What is key #5?
Coupled manufacturing
Anyone could find any file within one minute.
Quick changeover technology
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

48. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Filming someone with a light on their finger so you can see the movements to better improve the design.
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.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

49. What is level four of key 5?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Emphasize the connections between processes and full employee participation in improvement making
You have to communicate! Coordinate where the output is going to be stored.

50. Full work systems
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Cycle time - work sequence - standard inventory
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
It's hard because it deals with attitudes of employees.