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Lean Management

Instructions:

Answer 50 questions in 15 minutes.
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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 steps in Shingo's changeover system?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Coupled manufacturing

2. What are the three principles of prevention?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Can only be done when the machine is stopped or shut down.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

3. What is level 4 of key 9?
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 factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

4. What is product flow charting?
You have to communicate! Coordinate where the output is going to be stored.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Study the flow of a product through the various operations

5. What does TPM do?
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)
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
Prevents equipment from breaking down or malfunctioning.

6. At level three of key 6 - what is the methodology employees have been trained to use?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Cycle time - work sequence - standard inventory
Industrial engineering methodologies
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

7. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Study the flow of a product through the various operations
Machines work together to prevent overproduction - it stops once it meets demands.
Industrial engineering methodologies

8. What is push production?

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9. What is level 3 of key 9?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Staying competitive with yesterday's products is difficult - if not impossible.
Operators know they must keep their machines in good condition and eliminate the three evils.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

10. What is level four of key 5?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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'.
Maintaining equipment

11. What is level five of key 6?
Knowledge - Job security - Safety - Simplicity
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
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

12. What is level 4 of key 10?
Inventory waste - Delay - Declining quality
Can only be done when the machine is stopped or shut down.
Workers are conscientious about sticking to the work throughout the designated working areas.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

13. What are the three key technical activities in a TPM program?
Workers are conscientious about sticking to the work throughout the designated working areas.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Preventative maintenance - Prevention maintenance - Corrective prevention
Coupled manufacturing

14. What is level 5 of key 10?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Zero monitor manufacturing
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

15. What is Industrial Engineering?
Can be done while the machine is still processing.
Executives do not understand the high rate of return linked to integrated improvement.
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
Hands-on activity based on the facts - not opinion.

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

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17. What is level 3 of key 10?
Supervisors meet to work out time control issues
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
There is a shotgun approach to improvements; people have little concern for improving methods.
Involving production employees in the total machine maintenance process.

18. What is level 2 of key 9?
Inventory waste - Delay - Declining quality
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.
Everyone understands the need for PM; PM has been implemented for the most important machines.

19. What are the flowcharting rules of construction?
Video tape a person doing this so they can review what they're doing and improve.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Study the movement and motions of a worker or associate
Zero monitor manufacturing

20. What are the 5 pillars of TPM?

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21. What is level five of key 8?
Knowledge - Job security - Safety - Simplicity
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Manufacturing value analysis
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.

22. What are the functions and rules of kanban?
Determining the life expectancy of components in order to replace them at the optimum time.
Doubling productivity - Productivity = Output / TEE
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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

23. What is kaikaku?
You have to communicate! Coordinate where the output is going to be stored.
Large scale improvement
Time measuring
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.

24. What is level two of key 7?
Helps you understand the facts as they are.
Everyone recognizes that monitoring is waste
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

25. What is cycle time?
Time it takes to make one unit
Anyone could find any file within one minute.
You have to communicate! Coordinate where the output is going to be stored.
Run the machines into the ground

26. What is level three of key 5?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Study the movement and motions of a worker or associate
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.

27. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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
Continuous improvement of person and process
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

28. What is key #9?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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
Time measuring
Maintaining equipment

29. What does kanban do?
Eliminate certain processes that produce or create waste.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

30. What is level three of key 7?
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
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Industrial engineering methodologies

31. What is the strategic business development loop?
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.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Executives do not understand the high rate of return linked to integrated improvement.

32. What is the 'Six-Tenths Rule'?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Prevents equipment from breaking down or malfunctioning.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Made the basic elements of human motion (therbligs)

33. What is takt time?
To eliminate the big 3.
One operator handling several machines or processes
The available production time divided by the rate of customer demand
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 are the benefits of quick changeover for companies?
Zero monitor manufacturing
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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

35. What is level 1 of key 10?

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36. What does manufacturing value analysis do?
To eliminate the big 3.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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

37. What are the basic steps in a traditional changeover?
Can be done while the machine is still processing.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Study the movement and motions of a worker or associate
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)

38. What are the five components of TPM?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
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
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'.

39. What is single file retrieval?
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
Large scale improvement
Anyone could find any file within one minute.
Video tape a person doing this so they can review what they're doing and improve.

40. What is 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.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Quick changeover technology
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

41. What is an internal setup element?
To eliminate the big 3.
Can only be done when the machine is stopped or shut down.
Quick changeover technology
Workers are conscientious about sticking to the work throughout the designated working areas.

42. What is full work system?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Determining the life expectancy of components in order to replace them at the optimum time.
It's hard because it deals with attitudes of employees.
Machines work together to prevent overproduction - it stops once it meets demands.

43. What is level three of key 6?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
People have learned how to make systematic improvements at each process.
Everyone understands the need for PM; PM has been implemented for the most important machines.
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'.

44. What are the motions that slow down Type 1 motions?
Hands-on activity based on the facts - not opinion.
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'.
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)
Eliminate certain processes that produce or create waste.

45. What is level two of key 8?
Coupled manufacturing
Emphasize the connections between processes and full employee participation in improvement making
Study the movement and motions of a worker or associate
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

46. What is level three of 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.
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.
No one realizes that monitoring is waste - not work
Factory employees begin setting up inter-process stores

47. What is the value of TPM?
Can be done while the machine is still processing.
Contamination - inadequate lubrication - misoperation
Operators know they must keep their machines in good condition and eliminate the three evils.
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.

48. What is the purpose of Therblig analysis?
Helps you understand the facts as they are.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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.
The available production time divided by the rate of customer demand

49. What are the different types of motions required for performing an operation? (Type 1 motions)
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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
Continuous improvement of person and process

50. What are the steps in motion study?
Inventory waste - Delay - Declining quality
Each section does its own thing; each workplace functions independently
Preventative maintenance - Prevention maintenance - Corrective prevention
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation