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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 level five of key 5?
Coupled manufacturing
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
People have learned how to make systematic improvements at each process.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

2. What is level five of key 6?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Can only be done when the machine is stopped or shut down.
One operator handling several machines or processes
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

3. What is level three of key 8?
Factory employees begin setting up inter-process stores
Machines work together to prevent overproduction - it stops once it meets demands.
Each section does its own thing; each workplace functions independently
Coupled manufacturing

4. What is key #9?
Can only be done when the machine is stopped or shut down.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Maintaining equipment

5. What is the purpose of operator flow charting?
Executives do not understand the high rate of return linked to integrated improvement.
Time measuring
No one realizes that monitoring is waste - not work
Eliminate certain processes that produce or create waste.

6. What is level 4 of key 9?
There is a shotgun approach to improvements; people have little concern for improving methods.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

7. What is kaikaku?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Large scale improvement

8. What is an external setup element?
Large scale improvement
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.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Can be done while the machine is still processing.

9. What is prevention maintenance?
Emphasize the connections between processes and full employee participation in improvement making
Time control and commitment
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Double capacity and the per unit production cost is 60% of the lower capacity option.

10. What is level one of key 7?
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
No one realizes that monitoring is waste - not work
To eliminate the big 3.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

11. What is cycle time?
Time it takes to make one unit
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

12. What are the three key technical activities in a TPM program?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Preventative maintenance - Prevention maintenance - Corrective prevention
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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 level 3 of key 9?
Operators know they must keep their machines in good condition and eliminate the three evils.
Backorders create complacency.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Doubling productivity - Productivity = Output / TEE

14. What is focused improvement?

15. 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
Quick changeover studies begin; some employees are learning how to implement single changeover.
Prevents equipment from breaking down or malfunctioning.
Coupled manufacturing

16. What is key 10?
Time control and commitment
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Emphasize the connections between processes and full employee participation in improvement making

17. What does manufacturing value analysis do?
To eliminate the big 3.
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
Preventative maintenance - Prevention maintenance - Corrective prevention
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

18. What are the three elements of the standard work sheet?
To eliminate the big 3.
Machines work together to prevent overproduction - it stops once it meets demands.
Cycle time - work sequence - standard inventory
Determining the life expectancy of components in order to replace them at the optimum time.

19. What is key #8?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Coupled manufacturing
Operators know they must keep their machines in good condition and eliminate the three evils.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal

20. What is multi-process handling?
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.
One operator handling several machines or processes
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

21. 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
Machines work together to prevent overproduction - it stops once it meets demands.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Workers are conscientious about sticking to the work throughout the designated working areas.

22. What is level 2 of key 9?
Morning pep talk meetings are held everyday
Each section does its own thing; each workplace functions independently
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Everyone understands the need for PM; PM has been implemented for the most important machines.

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

24. What is takt time?
Knowledge - Job security - Safety - Simplicity
Study the movement and motions of a worker or associate
The available production time divided by the rate of customer demand
Helps you understand the facts as they are.

25. 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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

26. What is the make/ship loop?
Backorders create complacency.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
You want to equalize your work loads in terms of your lot size - one-piece flow.

27. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Zero monitor manufacturing
You want to equalize your work loads in terms of your lot size - one-piece flow.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

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

29. What is autonomation (Jidoka)?
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.
Knowledge - Job security - Safety - Simplicity
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Backorders create complacency.

30. What is level 1 of key 9?
Run the machines into the ground
Emphasize the connections between processes and full employee participation in improvement making
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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

31. What is the purpose of Cyclegraphic analysis?
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
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Cycle time - work sequence - standard inventory

32. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Coupled manufacturing
The customer's order starts the process
Everyone understands the need for PM; PM has been implemented for the most important machines.

33. What is level 1 of key 10?

34. What is the goal of motion study?
Maintaining equipment
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
To eliminate the big 3.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

35. What is the 'Six-Tenths Rule'?
To eliminate the big 3.
Determining the life expectancy of components in order to replace them at the optimum time.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Double capacity and the per unit production cost is 60% of the lower capacity option.

36. What is the strategic business development loop?
Executives do not understand the high rate of return linked to integrated improvement.
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'.
Workers are conscientious about sticking to the work throughout the designated working areas.

37. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
No one realizes that monitoring is waste - not work
All machines can operate during lunch without monitoring and many operators can handle two or more machines

38. What is level two of key 5?
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'.
Quick changeover studies begin; some employees are learning how to implement single changeover.
Time measuring
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

39. At level three of key 6 - what is the methodology employees have been trained to use?
Industrial engineering methodologies
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Can be done while the machine is still processing.
Executives do not understand the high rate of return linked to integrated improvement.

40. What is level two of key 6?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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.
Manufacturing value analysis

41. What is the purpose of video analysis?

42. What are the steps in motion study?
Eliminate certain processes that produce or create waste.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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.
To eliminate the big 3.

43. What are the motions that slow down Type 1 motions?
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)
People have learned how to make systematic improvements at each process.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

44. What is kaizen?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Factory employees begin setting up inter-process stores
Continuous improvement of person and process
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 the order processing and distribution loops?

46. What is level four of key 5?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Anyone could find any file within one minute.
Filming someone with a light on their finger so you can see the movements to better improve the design.

47. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Doubling productivity - Productivity = Output / TEE
Time measuring
Time it takes to make one unit

48. What are the benefits of properly maintaining equipment?
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
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Helps you understand the facts as they are.

49. What is single file retrieval?
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
Time it takes to make one unit
Helps you understand the facts as they are.
Anyone could find any file within one minute.

50. What are the different types of motions required for performing an operation? (Type 1 motions)
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Work and break times are left to the workers' discretion
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary