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 production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of 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
Knowledge - Job security - Safety - Simplicity


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

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3. What is focused improvement?

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4. What has to be done to get to level two of key 8?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
You have to communicate! Coordinate where the output is going to be stored.
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.


5. What are the benefits of quick changeover for companies?
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
The available production time divided by the rate of customer demand
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


6. What is level 2 of key 9?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
There is a shotgun approach to improvements; people have little concern for improving methods.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Time control and commitment


7. What is key #5?
Video tape a person doing this so they can review what they're doing and improve.
Morning pep talk meetings are held everyday
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Quick changeover technology


8. What are the process improvement steps?
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
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.
Morning pep talk meetings are held everyday


9. What is preventative maintenance?
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)
Identifying problems before they cause breakdowns.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
There is a shotgun approach to improvements; people have little concern for improving methods.


10. What is level two of key 5?
Zero monitor manufacturing
Quick changeover studies begin; some employees are learning how to implement single changeover.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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.


11. What is level five of key 5?
Morning pep talk meetings are held everyday
Double capacity and the per unit production cost is 60% of the lower capacity option.
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


12. What does kanban do?
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.
Supervisors meet to work out time control issues
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.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


13. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Work and break times are left to the workers' discretion
No one realizes that monitoring is waste - not work


14. What are the functions and rules of kanban?
Morning pep talk meetings are held everyday
Determining the life expectancy of components in order to replace them at the optimum time.
Identifying problems before they cause breakdowns.
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


15. What is level one of key 8?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Time measuring
Each section does its own thing; each workplace functions independently
Time control and commitment


16. What is the trouble with large-lot production?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Inventory waste - Delay - Declining quality
To eliminate the big 3.


17. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
Operators know they must keep their machines in good condition and eliminate the three evils.
People have learned how to make systematic improvements at each process.
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


18. What is product flow charting?
Study the flow of a product through the various operations
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Machines work together to prevent overproduction - it stops once it meets demands.
Coupled manufacturing


19. What is key 10?
Determining the life expectancy of components in order to replace them at the optimum time.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Manufacturing value analysis
Time control and commitment


20. What is the make/ship loop?
Contamination - inadequate lubrication - misoperation
Large scale improvement
Backorders create complacency.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance


21. What is level three of key 6?
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.
Everyone understands the need for PM; PM has been implemented for the most important machines.
People have learned how to make systematic improvements at each process.
Continuous improvement of person and process


22. What is level two of key 6?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Hands-on activity based on the facts - not opinion.
Large scale improvement


23. What is single file retrieval?
Coupled manufacturing
Anyone could find any file within one minute.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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


24. What are the motions that slow down Type 1 motions?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
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)
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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


25. What is the main goal of MVA?
Continuous improvement of person and process
Doubling productivity - Productivity = Output / TEE
Run the machines into the ground
All machines can operate during lunch without monitoring and many operators can handle two or more machines


26. What is takt time?
Everyone understands the need for PM; PM has been implemented for the most important machines.
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.
Work and break times are left to the workers' discretion
The available production time divided by the rate of customer demand


27. What is the goal of motion study?
To eliminate the big 3.
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
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


28. What is level four of key 7?
Determining the life expectancy of components in order to replace them at the optimum time.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Cycle time - work sequence - standard inventory


29. What is cycle time?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Time it takes to make one unit
Double capacity and the per unit production cost is 60% of the lower capacity option.
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


30. What is the purpose of video analysis?

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31. What are the 5 pillars of TPM?

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32. What is the purpose of Cyclegraphic analysis?
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.
Run the machines into the ground
Made the basic elements of human motion (therbligs)
Filming someone with a light on their finger so you can see the movements to better improve the design.


33. What is kaizen?
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 is applied to all machines and all parts; working toward even shorter cycle-time changeover
Continuous improvement of person and process
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


34. What are the three elements of the standard work sheet?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Cycle time - work sequence - standard inventory
Run the machines into the ground


35. What is prevention maintenance?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
There is a shotgun approach to improvements; people have little concern for improving methods.
Everyone recognizes that monitoring is waste
Doubling productivity - Productivity = Output / TEE


36. What is level one of key 6?
Study the flow of a product through the various operations
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
There is a shotgun approach to improvements; people have little concern for improving methods.
Backorders create complacency.


37. What is autonomation (Jidoka)?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Double capacity and the per unit production cost is 60% of the lower capacity option.
The customer's order starts the process
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


38. What is the order processing and distribution loops?

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39. What is level two of key 7?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Machines work together to prevent overproduction - it stops once it meets demands.
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
Everyone recognizes that monitoring is waste


40. What are the steps in motion study?
Each section does its own thing; each workplace functions independently
Study the movement and motions of a worker or associate
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Run the machines into the ground


41. What is level four of key 5?
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.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
One operator handling several machines or processes


42. What is push production?

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43. What is an external setup element?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Can be done while the machine is still processing.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance


44. 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.
Quick changeover technology
No one realizes that monitoring is waste - not work
It's hard because it deals with attitudes of employees.


45. What is predictive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Executives do not understand the high rate of return linked to integrated improvement.
Determining the life expectancy of components in order to replace them at the optimum time.
Anyone could find any file within one minute.


46. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Backorders create complacency.
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
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)


47. What is level 4 of key 10?
Workers are conscientious about sticking to the work throughout the designated working areas.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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)
Identifying problems before they cause breakdowns.


48. What is autonomous maintenance?
Prevents equipment from breaking down or malfunctioning.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Everyone recognizes that monitoring is waste
Involving production employees in the total machine maintenance process.


49. What is level one of key 7?
Workers are conscientious about sticking to the work throughout the designated working areas.
No one realizes that monitoring is waste - not work
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Manufacturing value analysis


50. What are the steps in Shingo's changeover system?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Continuous improvement of person and process
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation