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 the warning Kobayashi gives with respect to Key 10?

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2. What is level one of key 7?
Morning pep talk meetings are held everyday
No one realizes that monitoring is waste - not work
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Maintain normal conditions - early discovery of abnormalities - and prompt response.


3. What is key #5?
Study the flow of a product through the various operations
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Quick changeover technology
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.


4. What does manufacturing value analysis do?
Knowledge - Job security - Safety - Simplicity
Time control and commitment
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.


5. What are the three pillars of lean systems?
The customer's order starts the process
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Can be done while the machine is still processing.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


6. What is operator flow charting?
Study the movement and motions of a worker or associate
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


7. What are the benefits of properly maintaining equipment?
Anyone could find any file within one minute.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Double capacity and the per unit production cost is 60% of the lower capacity option.
One operator handling several machines or processes


8. What is kaikaku?
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)
Executives do not understand the high rate of return linked to integrated improvement.
Large scale improvement


9. Full work systems
Manufacturing value analysis
Backorders create complacency.
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
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


10. What is level four of key 5?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Industrial engineering methodologies
Backorders create complacency.
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?
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.
Large scale improvement
Inventory waste - Delay - Declining quality
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


12. What is focused improvement?

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13. What are the functions and rules of kanban?
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
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
One operator handling several machines or processes
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


14. What has to be done to get to level two of key 8?
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.
The customer's order starts the process
Doubling productivity - Productivity = Output / TEE
You have to communicate! Coordinate where the output is going to be stored.


15. What is level three of key 8?
Factory employees begin setting up inter-process stores
Identifying problems before they cause breakdowns.
Cycle time - work sequence - standard inventory
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


16. What is the purpose of flowcharting?
One operator handling several machines or processes
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
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'.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


17. What is the purpose of video analysis?

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18. What is the purpose of Cyclegraphic analysis?
Made the basic elements of human motion (therbligs)
Filming someone with a light on their finger so you can see the movements to better improve the design.
Continuous improvement of person and process
Can only be done when the machine is stopped or shut down.


19. What is preventative maintenance?
Study the movement and motions of a worker or associate
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Identifying problems before they cause breakdowns.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.


20. What is level five of key 7?
Inventory waste - Delay - Declining quality
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Determining the life expectancy of components in order to replace them at the optimum time.


21. What is full work system?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Machines work together to prevent overproduction - it stops once it meets demands.
Video tape a person doing this so they can review what they're doing and improve.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


22. What is the purpose of Therblig analysis?
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.
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.
Executives do not understand the high rate of return linked to integrated improvement.


23. What does TPM do?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Prevents equipment from breaking down or malfunctioning.
Inventory waste - Delay - Declining quality
No one realizes that monitoring is waste - not work


24. What are the benefits of quick changeover for associates?
People have learned how to make systematic improvements at each process.
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
Maintaining equipment
Knowledge - Job security - Safety - Simplicity


25. What is level three of key 5?
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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Continuous improvement of person and process
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


26. What is autonomous maintenance?
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.
Continuous improvement of person and process
Involving production employees in the total machine maintenance process.


27. What are the three evils?
Contamination - inadequate lubrication - misoperation
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
Involving production employees in the total machine maintenance process.


28. What is level four of key 8?
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'.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
People have learned how to make systematic improvements at each process.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign


29. What is level 2 of key 10?
Can be done while the machine is still processing.
Time it takes to make one unit
Morning pep talk meetings are held everyday
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.


30. What is the purpose of operator flow charting?
Each section does its own thing; each workplace functions independently
You have to communicate! Coordinate where the output is going to be stored.
Eliminate certain processes that produce or create waste.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


31. What are the process improvement steps?
Operators know they must keep their machines in good condition and eliminate the three evils.
To eliminate the big 3.
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


32. What is an external setup element?
Time it takes to make one unit
Run the machines into the ground
Can be done while the machine is still processing.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


33. What is the purpose of Chronocyclegraphic analysis?
Study the movement and motions of a worker or associate
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
Staying competitive with yesterday's products is difficult - if not impossible.
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.


34. What is level 4 of key 9?
Continuous improvement of person and process
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
Maintain normal conditions - early discovery of abnormalities - and prompt response.


35. What are the motions that slow down Type 1 motions?
Preventative maintenance - Prevention maintenance - Corrective prevention
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)
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.
Machines work together to prevent overproduction - it stops once it meets demands.


36. What are the five components of TPM?
There is a shotgun approach to improvements; people have little concern for improving methods.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
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


37. What is level two of key 5?
Time it takes to make one unit
The customer's order starts the process
You want to equalize your work loads in terms of your lot size - one-piece flow.
Quick changeover studies begin; some employees are learning how to implement single changeover.


38. What is key #8?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Coupled manufacturing
Involving production employees in the total machine maintenance process.


39. What are the benefits of quick changeover for companies?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Everyone understands the need for PM; PM has been implemented for the most important machines.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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


40. What does kanban do?
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.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Continuous improvement of person and process


41. What is single file retrieval?
Anyone could find any file within one minute.
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)
Everyone understands the need for PM; PM has been implemented for the most important machines.
Executives do not understand the high rate of return linked to integrated improvement.


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

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43. What is the new product introduction loop?

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44. What is level 5 of key 9?
Doubling productivity - Productivity = Output / TEE
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
Double capacity and the per unit production cost is 60% of the lower capacity option.


45. What is level two of key 7?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Everyone recognizes that monitoring is waste
Double capacity and the per unit production cost is 60% of the lower capacity option.
Workers are conscientious about sticking to the work throughout the designated working areas.


46. At level three of key 6 - what is the methodology employees have been trained to use?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Can be done while the machine is still processing.
Industrial engineering methodologies


47. What is level 1 of key 10?

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48. What is kaizen?
Large scale improvement
Maintaining equipment
Continuous improvement of person and process
Coupled manufacturing


49. What is the trouble with large-lot production?
Can only be done when the machine is stopped or shut down.
Time measuring
Inventory waste - Delay - Declining quality
Machines work together to prevent overproduction - it stops once it meets demands.


50. What is level 5 of key 10?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Morning pep talk meetings are held everyday
You want to equalize your work loads in terms of your lot size - one-piece flow.
Filming someone with a light on their finger so you can see the movements to better improve the design.