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 2 of key 9?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Study the movement and motions of a worker or associate
Time control and commitment
Everyone understands the need for PM; PM has been implemented for the most important machines.


2. What is focused improvement?

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3. 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
Time it takes to make one unit
Prevents equipment from breaking down or malfunctioning.
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


4. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
Identifying problems before they cause breakdowns.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Study the movement and motions of a worker or associate


5. What are the three key technical activities in a TPM program?
Manufacturing value analysis
Can only be done when the machine is stopped or shut down.
Preventative maintenance - Prevention maintenance - Corrective prevention
Large scale improvement


6. What did Frank Gilbreth do?
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
One operator handling several machines or processes
Made the basic elements of human motion (therbligs)
Staying competitive with yesterday's products is difficult - if not impossible.


7. At level three of key 6 - what is the methodology employees have been trained to use?
Anyone could find any file within one minute.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Industrial engineering methodologies
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


8. What is level 5 of key 9?
Can only be done when the machine is stopped or shut down.
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 improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.


9. What are the three evils?
Manufacturing value analysis
Contamination - inadequate lubrication - misoperation
Continuous improvement of person and process
Determining the life expectancy of components in order to replace them at the optimum time.


10. What is the order processing and distribution loops?

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11. What is level two of key 7?
Preventative maintenance - Prevention maintenance - Corrective prevention
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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
Everyone recognizes that monitoring is waste


12. What is kaizen?
Determining the life expectancy of components in order to replace them at the optimum time.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Continuous improvement of person and process
Made the basic elements of human motion (therbligs)


13. What are the different types of motions required for performing an operation? (Type 1 motions)
Industrial engineering methodologies
Machines work together to prevent overproduction - it stops once it meets demands.
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.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


14. What is multi-process handling?
Involving production employees in the total machine maintenance process.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Time measuring
One operator handling several machines or processes


15. What is preventative maintenance?
Backorders create complacency.
Identifying problems before they cause breakdowns.
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.
Time control and commitment


16. What is level one of key 7?
No one realizes that monitoring is waste - not work
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'.
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)
You want to equalize your work loads in terms of your lot size - one-piece flow.


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

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18. What is the purpose of Cyclegraphic analysis?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Study the movement and motions of a worker or associate
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
All machines can operate during lunch without monitoring and many operators can handle two or more machines


19. 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
Quick changeover technology
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
Work and break times are left to the workers' discretion


20. What is key #9?
Time it takes to make one unit
Maintaining equipment
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Run the machines into the ground


21. What does manufacturing value analysis do?
Continuous improvement of person and process
Can be done while the machine is still processing.
Workers are conscientious about sticking to the work throughout the designated working areas.
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


22. What are the five components of TPM?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Factory employees begin setting up inter-process stores


23. What is the purpose of operator flow charting?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Identifying problems before they cause breakdowns.
Eliminate certain processes that produce or create waste.
Involving production employees in the total machine maintenance process.


24. What is key #6?
Video tape a person doing this so they can review what they're doing and improve.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Industrial engineering methodologies
Manufacturing value analysis


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

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26. What is level one of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Preventative maintenance - Prevention maintenance - Corrective prevention
Double capacity and the per unit production cost is 60% of the lower capacity option.
Knowledge - Job security - Safety - Simplicity


27. What is key #5?
There is a shotgun approach to improvements; people have little concern for improving methods.
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.
Quick changeover technology
Inventory waste - Delay - Declining quality


28. What is the make/ship loop?
Can be done while the machine is still processing.
The customer's order starts the process
Backorders create complacency.
Maintain normal conditions - early discovery of abnormalities - and prompt response.


29. What is level 1 of key 10?

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30. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
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
Each section does its own thing; each workplace functions independently
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


31. What is level five of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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.
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
There is a shotgun approach to improvements; people have little concern for improving methods.


32. What is key #8?
Identifying problems before they cause breakdowns.
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
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
Coupled manufacturing


33. What is level four of key 5?
It's hard because it deals with attitudes of employees.
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.
Eliminate certain processes that produce or create waste.


34. What is the strategic business development loop?
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'.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Anyone could find any file within one minute.
Executives do not understand the high rate of return linked to integrated improvement.


35. What is the purpose of Chronocyclegraphic 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.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Helps you understand the facts as they are.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


36. What are the 6 Big Losses of TPM?
Anyone could find any file within one minute.
Doubling productivity - Productivity = Output / TEE
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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


37. What are the three principles of prevention?
It's hard because it deals with attitudes of employees.
You have to communicate! Coordinate where the output is going to be stored.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


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

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39. What is level four of key 7?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Video tape a person doing this so they can review what they're doing and improve.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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)


40. What is the trouble with large-lot production?
Inventory waste - Delay - Declining quality
Work and break times are left to the workers' discretion
Can be done while the machine is still processing.
Anyone could find any file within one minute.


41. What is level three 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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Backorders create complacency.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


42. What is key #7?
Backorders create complacency.
Zero monitor manufacturing
Time measuring
Staying competitive with yesterday's products is difficult - if not impossible.


43. What is autonomous maintenance?
Video tape a person doing this so they can review what they're doing and improve.
Involving production employees in the total machine maintenance process.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
The available production time divided by the rate of customer demand


44. What is level 2 of key 10?
Morning pep talk meetings are held everyday
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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
Determining the life expectancy of components in order to replace them at the optimum time.


45. What are the 5 pillars of TPM?

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46. What is level 3 of key 9?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Operators know they must keep their machines in good condition and eliminate the three evils.
Time measuring


47. What is level 4 of key 9?
Anyone could find any file within one minute.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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 customer's order starts the process


48. What are the three elements of the standard work sheet?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Cycle time - work sequence - standard inventory
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Helps you understand the facts as they are.


49. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Machines work together to prevent overproduction - it stops once it meets demands.
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.


50. What is the new product introduction loop?

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