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 three key technical activities in a TPM program?
Zero monitor manufacturing
Preventative maintenance - Prevention maintenance - Corrective prevention
Work and break times are left to the workers' discretion
Industrial engineering methodologies


2. What is the purpose of video analysis?

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3. What has to be done to get to level two of key 8?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Anyone could find any file within one minute.
Each section does its own thing; each workplace functions independently
You have to communicate! Coordinate where the output is going to be stored.


4. What is the make/ship loop?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Backorders create complacency.
Preventative maintenance - Prevention maintenance - Corrective prevention


5. What does manufacturing value analysis do?
Everyone recognizes that monitoring is waste
One operator handling several machines or processes
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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


6. What is level five of key 7?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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
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
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


7. What is the goal of motion study?
No one realizes that monitoring is waste - not work
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
To eliminate the big 3.
All machines can operate during lunch without monitoring and many operators can handle two or more machines


8. What is level one 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
Video tape a person doing this so they can review what they're doing and improve.
Each section does its own thing; each workplace functions independently
Coupled manufacturing


9. 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.
Study the movement and motions of a worker or associate
Inventory waste - Delay - Declining quality
Run the machines into the ground


10. What is cycle time?
It's hard because it deals with attitudes of employees.
Time it takes to make one unit
Can only be done when the machine is stopped or shut down.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


11. What is the purpose of Therblig analysis?
Helps you understand the facts as they are.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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'.


12. What are the flowcharting rules of construction?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Coupled manufacturing
Hands-on activity based on the facts - not opinion.
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


13. What is key 10?
Each section does its own thing; each workplace functions independently
Time control and commitment
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


14. What are the 6 Big Losses of TPM?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Involving production employees in the total machine maintenance process.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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


15. What is preventive maintenance?
Video tape a person doing this so they can review what they're doing and improve.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


16. What is prevention maintenance?
Video tape a person doing this so they can review what they're doing and improve.
No one realizes that monitoring is waste - not work
It's hard because it deals with attitudes of employees.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


17. What is key #6?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Contamination - inadequate lubrication - misoperation
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Manufacturing value analysis


18. 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.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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.


19. What are the benefits of quick changeover for associates?
Factory employees begin setting up inter-process stores
Knowledge - Job security - Safety - Simplicity
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.
Run the machines into the ground


20. What is level three of key 8?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Factory employees begin setting up inter-process stores
People have learned how to make systematic improvements at each process.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


21. What is the new product introduction loop?

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22. What are the process improvement steps?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
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
Can be done while the machine is still processing.


23. What is level 5 of key 9?
People have learned how to make systematic improvements at each process.
Work and break times are left to the workers' discretion
There is a shotgun approach to improvements; people have little concern for improving methods.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.


24. At level three of key 6 - what is the methodology employees have been trained to use?
The customer's order starts the process
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Industrial engineering methodologies
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.


25. What is the order processing and distribution loops?

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26. What is level four of key 6?
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
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
It's hard because it deals with attitudes of employees.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


27. What is key #9?
One operator handling several machines or processes
Maintaining equipment
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
Contamination - inadequate lubrication - misoperation


28. What is takt time?
The available production time divided by the rate of customer demand
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Work and break times are left to the workers' discretion


29. What is level five of key 8?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Filming someone with a light on their finger so you can see the movements to better improve the design.
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
There is a shotgun approach to improvements; people have little concern for improving methods.


30. What is kaikaku?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Involving production employees in the total machine maintenance process.
Large scale improvement
Preventative maintenance - Prevention maintenance - Corrective prevention


31. What is push production?

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32. What is production leveling?
Supervisors meet to work out time control issues
Eliminate certain processes that produce or create waste.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.


33. What is level 3 of key 9?
Large scale improvement
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.
Manufacturing value analysis
Operators know they must keep their machines in good condition and eliminate the three evils.


34. What are the three pillars of lean systems?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Made the basic elements of human motion (therbligs)
Prevents equipment from breaking down or malfunctioning.


35. What is an external setup element?
Can be done while the machine is still processing.
Work and break times are left to the workers' discretion
Contamination - inadequate lubrication - misoperation
Time control and commitment


36. What are the different types of motions required for performing an operation? (Type 1 motions)
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
Identifying problems before they cause breakdowns.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


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

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38. What are the steps in motion study?
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
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Factory employees begin setting up inter-process stores
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


39. What is the purpose of flowcharting?
No one realizes that monitoring is waste - not work
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


40. What is an internal setup element?
Morning pep talk meetings are held everyday
Can only be done when the machine is stopped or shut down.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


41. What is product flow charting?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Study the flow of a product through the various operations
You have to communicate! Coordinate where the output is going to be stored.
Involving production employees in the total machine maintenance process.


42. Full work systems
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
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Study the movement and motions of a worker or associate
Inventory waste - Delay - Declining quality


43. What is the strategic business development loop?
Executives do not understand the high rate of return linked to integrated improvement.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Cycle time - work sequence - standard inventory
Emphasize the connections between processes and full employee participation in improvement making


44. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Each section does its own thing; each workplace functions independently
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


45. What is level two of key 5?
Determining the life expectancy of components in order to replace them at the optimum time.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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.


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

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47. What is the value of TPM?
Involving production employees in the total machine maintenance process.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Prevents equipment from breaking down or malfunctioning.
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 did Frank Gilbreth do?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Made the basic elements of human motion (therbligs)
Maintaining equipment
Inventory waste - Delay - Declining quality


49. What are the three elements of the standard work sheet?
Helps you understand the facts as they are.
Cycle time - work sequence - standard inventory
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Doubling productivity - Productivity = Output / TEE


50. What is level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Morning pep talk meetings are held everyday