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 preventive maintenance?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Large scale improvement
Study the flow of a product through the various operations

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

3. What is key #8?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Coupled manufacturing
Contamination - inadequate lubrication - misoperation
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

4. What are the benefits of quick changeover for associates?
People have learned how to make systematic improvements at each process.
Knowledge - Job security - Safety - Simplicity
Quick changeover studies begin; some employees are learning how to implement single changeover.
Can be done while the machine is still processing.

5. What are the 5 pillars of TPM?

6. What are the steps in Shingo's changeover system?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Industrial engineering methodologies
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
You want to equalize your work loads in terms of your lot size - one-piece flow.

7. What is key 10?
Can be done while the machine is still processing.
Involving production employees in the total machine maintenance process.
Time control and commitment
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

8. What is level 2 of key 10?
Morning pep talk meetings are held everyday
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'.
Coupled manufacturing
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

9. What is the main goal of MVA?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Doubling productivity - Productivity = Output / TEE
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

10. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Involving production employees in the total machine maintenance process.
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
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

11. What are the basic steps in a traditional changeover?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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.

12. What is push production?

13. What is level four of key 5?
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
Doubling productivity - Productivity = Output / TEE
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

14. What is takt time?
Time measuring
The available production time divided by the rate of customer demand
Preventative maintenance - Prevention maintenance - Corrective prevention
Inventory waste - Delay - Declining quality

15. What are the steps in motion study?
Helps you understand the facts as they are.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

16. What is key #9?
Involving production employees in the total machine maintenance process.
Maintaining equipment
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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

17. What are the five components of TPM?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

18. Full work systems
Maintaining equipment
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
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 only be done when the machine is stopped or shut down.

19. What is level three of key 7?
Manufacturing value analysis
The customer's order starts the process
Eliminate certain processes that produce or create waste.
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

20. What did Frank Gilbreth do?
Large scale improvement
There is a shotgun approach to improvements; people have little concern for improving methods.
Video tape a person doing this so they can review what they're doing and improve.
Made the basic elements of human motion (therbligs)

21. What is key #7?
Operators know they must keep their machines in good condition and eliminate the three evils.
Quick changeover technology
Zero monitor manufacturing
Backorders create complacency.

22. What is autonomation (Jidoka)?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

23. What are the three key technical activities in a TPM program?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Preventative maintenance - Prevention maintenance - Corrective prevention
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Each section does its own thing; each workplace functions independently

24. What is an external setup element?
Can be done while the machine is still processing.
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)
No one realizes that monitoring is waste - not work
Backorders create complacency.

25. What are the motions that slow down Type 1 motions?
Work and break times are left to the workers' discretion
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)
Emphasize the connections between processes and full employee participation in improvement making
No one realizes that monitoring is waste - not work

26. What is level 1 of key 10?

27. What are the process improvement steps?
Operators know they must keep their machines in good condition and eliminate the three evils.
Run the machines into the ground
Coupled 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

28. What is the purpose of Chronocyclegraphic analysis?
There is a shotgun approach to improvements; people have little concern for improving methods.
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.
Study the movement and motions of a worker or associate
Work and break times are left to the workers' discretion

29. What is level 5 of key 10?
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
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
All machines can operate during lunch without monitoring and many operators can handle two or more machines

30. What are the three principles of prevention?
Factory employees begin setting up inter-process stores
Maintain normal conditions - early discovery of abnormalities - and prompt response.
One operator handling several machines or processes
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

31. 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
Prevents equipment from breaking down or malfunctioning.
Industrial engineering methodologies
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

32. What is cycle time?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Time it takes to make one unit
Inventory waste - Delay - Declining quality
Contamination - inadequate lubrication - misoperation

33. What is focused improvement?

34. What are the benefits of properly maintaining equipment?
Inventory waste - Delay - Declining quality
Time measuring
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Video tape a person doing this so they can review what they're doing and improve.

35. What is the value of TPM?
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
The customer's order starts the process
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.
Staying competitive with yesterday's products is difficult - if not impossible.

36. What is the purpose of Therblig analysis?
Supervisors meet to work out time control issues
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
Work and break times are left to the workers' discretion
Helps you understand the facts as they are.

37. What is corrective maintenance?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Everyone understands the need for PM; PM has been implemented for the most important machines.

38. What are the motions that do not perform an operation?
There is a shotgun approach to improvements; people have little concern for improving methods.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

39. What are the functions and rules of kanban?
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.
Large scale 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
Preventative maintenance - Prevention maintenance - Corrective prevention

40. What is preventative maintenance?
The available production time divided by the rate of customer demand
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'.
Identifying problems before they cause breakdowns.
You have to communicate! Coordinate where the output is going to be stored.

41. What is level one of key 7?
Coupled manufacturing
No one realizes that monitoring is waste - not work
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Made the basic elements of human motion (therbligs)

42. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Doubling productivity - Productivity = Output / TEE
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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

43. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Video tape a person doing this so they can review what they're doing and improve.
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)

44. What is product flow charting?
Time control and commitment
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.
Study the flow of a product through the various operations
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.

45. What is Industrial Engineering?
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
Preventative maintenance - Prevention maintenance - Corrective prevention
Hands-on activity based on the facts - not opinion.
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.

46. What is key #5?
Quick changeover technology
Cycle time - work sequence - standard inventory
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
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.

47. What are the 6 Big Losses of TPM?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Run the machines into the ground
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
You want to equalize your work loads in terms of your lot size - one-piece flow.

48. What is operator flow charting?
Involving production employees in the total machine maintenance process.
Study the movement and motions of a worker or associate
Time measuring
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

49. What is level two of key 7?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Everyone recognizes that monitoring is waste
Identifying problems before they cause breakdowns.
Machines work together to prevent overproduction - it stops once it meets demands.

50. What is level five of key 5?
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)
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
It's hard because it deals with attitudes of employees.