Test your basic knowledge |

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 cycle time?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Supervisors meet to work out time control issues
Time it takes to make one unit

2. What is preventative maintenance?
Identifying problems before they cause breakdowns.
Time measuring
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'.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

3. What is level two of key 7?
Everyone recognizes that monitoring is waste
Determining the life expectancy of components in order to replace them at the optimum time.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Anyone could find any file within one minute.

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

5. What is the new product introduction loop?

6. What are the three elements of the standard work sheet?
Cycle time - work sequence - standard inventory
Zero monitor manufacturing
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Study the flow of a product through the various operations

7. At level three of key 6 - what is the methodology employees have been trained to use?
The available production time divided by the rate of customer demand
Preventative maintenance - Prevention maintenance - Corrective prevention
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Industrial engineering methodologies

8. What are the motions that do not perform an operation?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Maintaining equipment
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

9. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
Backorders create complacency.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
One operator handling several machines or processes

10. What are the different types of motions required for performing an operation? (Type 1 motions)
Quick changeover technology
Each section does its own thing; each workplace functions independently
Zero monitor manufacturing
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

11. What is level 4 of key 9?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Work and break times are left to the workers' discretion
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Time it takes to make one unit

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

13. What is level 3 of key 9?
Operators know they must keep their machines in good condition and eliminate the three evils.
Time it takes to make one unit
Involving production employees in the total machine maintenance process.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

14. What are the basic steps in a traditional changeover?
Operators know they must keep their machines in good condition and eliminate the three evils.
Maintaining equipment
Everyone recognizes that monitoring is waste
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

15. What are the benefits of quick changeover for companies?
Coupled manufacturing
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
Factory employees begin setting up inter-process stores
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

16. What is key #5?
Quick changeover technology
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation

17. What is the purpose of Therblig analysis?
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)
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Helps you understand the facts as they are.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

18. What is Industrial Engineering?
To eliminate the big 3.
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.
Emphasize the connections between processes and full employee participation in improvement making
Hands-on activity based on the facts - not opinion.

19. What is level 2 of key 9?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Knowledge - Job security - Safety - Simplicity
Coupled manufacturing
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

20. What is the main goal of MVA?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Doubling productivity - Productivity = Output / TEE
There is a shotgun approach to improvements; people have little concern for improving methods.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

21. What is level two of key 6?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Executives do not understand the high rate of return linked to integrated improvement.
Morning pep talk meetings are held everyday
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

22. What are the three principles of prevention?
Executives do not understand the high rate of return linked to integrated improvement.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Study the movement and motions of a worker or associate
Maintain normal conditions - early discovery of abnormalities - and prompt response.

23. What is push production?

24. What is the make/ship loop?
Backorders create complacency.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Operators know they must keep their machines in good condition and eliminate the three evils.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

25. What is level 5 of key 9?
No one realizes that monitoring is waste - not work
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Everyone understands the need for PM; PM has been implemented for the most important machines.

26. What is key #9?
The available production time divided by the rate of customer demand
Maintaining equipment
Prevents equipment from breaking down or malfunctioning.
Time measuring

27. What is operator flow charting?
Study the movement and motions of a worker or associate
No one realizes that monitoring is waste - not work
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.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

28. What is level five of key 7?
Study the flow of a product through the various operations
Morning pep talk meetings are held everyday
Double capacity and the per unit production cost is 60% of the lower capacity option.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

29. What is level four of key 5?
Factory employees begin setting up inter-process stores
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

30. What are the three evils?
Contamination - inadequate lubrication - misoperation
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Inventory waste - Delay - Declining quality
Can be done while the machine is still processing.

31. What is level four of key 6?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Machines work together to prevent overproduction - it stops once it meets demands.
Continuous improvement of person and process

32. What are the flowcharting rules of construction?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
It's hard because it deals with attitudes of employees.
No one realizes that monitoring is waste - not work
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

33. What is the strategic business development loop?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Executives do not understand the high rate of return linked to integrated improvement.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Staying competitive with yesterday's products is difficult - if not impossible.

34. What is autonomation (Jidoka)?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

35. What is the order processing and distribution loops?

36. What is level four of key 7?
Emphasize the connections between processes and full employee participation in improvement making
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Can only be done when the machine is stopped or shut down.
Made the basic elements of human motion (therbligs)

37. What is level two of key 5?
Inventory waste - Delay - Declining quality
Coupled manufacturing
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Quick changeover studies begin; some employees are learning how to implement single changeover.

38. What are the benefits of properly maintaining equipment?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Backorders create complacency.
Run the machines into the ground
Executives do not understand the high rate of return linked to integrated improvement.

39. What is level five of key 8?
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

40. What does TPM do?
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
There is a shotgun approach to improvements; people have little concern for improving methods.
Prevents equipment from breaking down or malfunctioning.
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

41. What is an internal setup element?
Zero monitor manufacturing
Executives do not understand the high rate of return linked to integrated improvement.
Can only be done when the machine is stopped or shut down.
Everyone understands the need for PM; PM has been implemented for the most important machines.

42. What are the steps in Shingo's changeover system?
Involving production employees in the total machine maintenance process.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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'.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

43. What is product flow charting?
Work and break times are left to the workers' discretion
Study the flow of a product through the various operations
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
To eliminate the big 3.

44. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Double capacity and the per unit production cost is 60% of the lower capacity option.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Factory employees begin setting up inter-process stores

45. What is key #8?
Coupled manufacturing
Continuous improvement of person and process
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.

46. What does kanban do?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

47. What are the three key technical activities in a TPM program?
Morning pep talk meetings are held everyday
Manufacturing value analysis
People have learned how to make systematic improvements at each process.
Preventative maintenance - Prevention maintenance - Corrective prevention

48. 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
Operators know they must keep their machines in good condition and eliminate the three evils.
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.

49. Full work systems
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.
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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

50. 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
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
No one realizes that monitoring is waste - not work
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.