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 steps in Shingo's changeover system?
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
Quick changeover technology
Prevents equipment from breaking down or malfunctioning.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


2. What is key #8?
Hands-on activity based on the facts - not opinion.
Staying competitive with yesterday's products is difficult - if not impossible.
Involving production employees in the total machine maintenance process.
Coupled manufacturing


3. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Large scale improvement
It's hard because it deals with attitudes of employees.


4. What is autonomous maintenance?
Morning pep talk meetings are held everyday
Everyone understands the need for PM; PM has been implemented for the most important machines.
Involving production employees in the total machine maintenance process.
Executives do not understand the high rate of return linked to integrated improvement.


5. What is push production?

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6. What is level 1 of key 10?

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7. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Machines work together to prevent overproduction - it stops once it meets demands.
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
Identifying problems before they cause breakdowns.


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

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9. 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
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Cycle time - work sequence - standard inventory


10. What has to be done to get to level two of key 8?
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.
You have to communicate! Coordinate where the output is going to be stored.
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
The available production time divided by the rate of customer demand


11. What is level 3 of key 10?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Supervisors meet to work out time control issues
Backorders create complacency.
There is a shotgun approach to improvements; people have little concern for improving methods.


12. What is level 3 of key 9?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Operators know they must keep their machines in good condition and eliminate the three evils.
Inventory waste - Delay - Declining quality


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

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14. What does TPM do?
Inventory waste - Delay - Declining quality
Video tape a person doing this so they can review what they're doing and improve.
Prevents equipment from breaking down or malfunctioning.
Involving production employees in the total machine maintenance process.


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

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16. What are the steps in motion study?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
The available production time divided by the rate of customer demand
Coupled manufacturing
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


17. What is preventive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Can be done while the machine is still processing.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Doubling productivity - Productivity = Output / TEE


18. What are the 6 Big Losses of TPM?
Morning pep talk meetings are held everyday
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
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
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


19. What is level 4 of key 9?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Made the basic elements of human motion (therbligs)


20. What is level one of key 6?
Study the flow of a product through the various operations
There is a shotgun approach to improvements; people have little concern for improving methods.
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.


21. What is level five of key 8?
No one realizes that monitoring is waste - not work
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Time measuring
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.


22. What is the trouble with large-lot production?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Inventory waste - Delay - Declining quality
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


23. What are the three pillars of lean systems?
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'.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
It's hard because it deals with attitudes of employees.
You want to equalize your work loads in terms of your lot size - one-piece flow.


24. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
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.
Run the machines into the ground
Supervisors meet to work out time control issues


25. What does manufacturing value analysis do?
Filming someone with a light on their finger so you can see the movements to better improve the design.
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
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
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


26. What is level 5 of key 10?
Determining the life expectancy of components in order to replace them at the optimum time.
Contamination - inadequate lubrication - misoperation
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Time measuring


27. What is key #9?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Run the machines into the ground
Maintaining equipment
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)


28. What is takt time?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
The available production time divided by the rate of customer demand
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
It's hard because it deals with attitudes of employees.


29. What is autonomation (Jidoka)?
Continuous improvement of person and process
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Hands-on activity based on the facts - not opinion.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


30. What is the purpose of video analysis?

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31. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Run the machines into the ground
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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


32. What is level two of key 6?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Inventory waste - Delay - Declining quality
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Time it takes to make one unit


33. What is level 1 of key 9?
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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Run the machines into the ground
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


34. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
Hands-on activity based on the facts - not opinion.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


35. What are the five components of TPM?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Machines work together to prevent overproduction - it stops once it meets demands.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


36. At level three of key 6 - what is the methodology employees have been trained to use?
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.
Industrial engineering methodologies
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Involving production employees in the total machine maintenance process.


37. What are the three elements of the standard work sheet?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
You want to equalize your work loads in terms of your lot size - one-piece flow.
Cycle time - work sequence - standard inventory
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs


38. What is level one of key 8?
Each section does its own thing; each workplace functions independently
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.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Factory employees begin setting up inter-process stores


39. 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
Everyone understands the need for PM; PM has been implemented for the most important machines.
Can only be done when the machine is stopped or shut down.


40. What is kaikaku?
Large scale improvement
You have to communicate! Coordinate where the output is going to be stored.
Zero monitor manufacturing
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


41. What is prevention maintenance?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Each section does its own thing; each workplace functions independently
Hands-on activity based on the facts - not opinion.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


42. 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.
Time control and commitment
The customer's order starts the process
The available production time divided by the rate of customer demand


43. What is level four of key 5?
People have learned how to make systematic improvements at each process.
The customer's order starts the process
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Cycle time - work sequence - standard inventory


44. What are the motions that do not perform an operation?
Determining the life expectancy of components in order to replace them at the optimum time.
Doubling productivity - Productivity = Output / TEE
Quick changeover studies begin; some employees are learning how to implement single changeover.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)


45. What is kaizen?
Continuous improvement of person and process
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Morning pep talk meetings are held everyday


46. What is key #5?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
You have to communicate! Coordinate where the output is going to be stored.
Quick changeover technology


47. What is level 4 of key 10?
Workers are conscientious about sticking to the work throughout the designated working areas.
Video tape a person doing this so they can review what they're doing and improve.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Everyone recognizes that monitoring is waste


48. What is level four of key 8?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments


49. What is level four of key 6?
The customer's order starts the process
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Prevents equipment from breaking down or malfunctioning.
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


50. What are the different types of motions required for performing an operation? (Type 1 motions)
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Time control and commitment
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Quick changeover studies begin; some employees are learning how to implement single changeover.