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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 6?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Factory employees begin setting up inter-process stores
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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.

2. What is level four of key 7?
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 be done while the machine is still processing.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
You want to equalize your work loads in terms of your lot size - one-piece flow.

3. What are the steps in Shingo's changeover system?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
It's hard because it deals with attitudes of employees.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Continuous improvement of person and process

4. Full work systems
Study the movement and motions of a worker or associate
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

5. What is key #9?
Large scale improvement
Maintaining equipment
There is a shotgun approach to improvements; people have little concern for improving methods.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

6. What is level two of key 6?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Time measuring
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
You want to equalize your work loads in terms of your lot size - one-piece flow.

7. What is level four of key 5?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Can be done while the machine is still processing.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

8. 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)
Eliminate certain processes that produce or create waste.
Knowledge - Job security - Safety - Simplicity
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

9. What is pull production?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
It's hard because it deals with attitudes of employees.
The available production time divided by the rate of customer demand
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

10. What is the purpose of operator flow charting?
Time control and commitment
Eliminate certain processes that produce or create waste.
Doubling productivity - Productivity = Output / TEE
Large scale improvement

11. What is prevention maintenance?
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.
Can only be done when the machine is stopped or shut down.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

12. What is kaikaku?
Large scale improvement
Time it takes to make one unit
Anyone could find any file within one minute.
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.

13. What is the strategic business development loop?
Factory employees begin setting up inter-process stores
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.
Executives do not understand the high rate of return linked to integrated improvement.

14. What is the main goal of MVA?
Operators know they must keep their machines in good condition and eliminate the three evils.
Inventory waste - Delay - Declining quality
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.
Doubling productivity - Productivity = Output / TEE

15. What is push production?

16. What is the 'Six-Tenths Rule'?
The available production time divided by the rate of customer demand
Double capacity and the per unit production cost is 60% of the lower capacity option.
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)
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

17. What are the five components of TPM?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Executives do not understand the high rate of return linked to integrated improvement.
Operators know they must keep their machines in good condition and eliminate the three evils.
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)

18. What is level 1 of key 9?
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
Run the machines into the ground
Contamination - inadequate lubrication - misoperation

19. What are the flowcharting rules of construction?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Run the machines into the ground
You have to communicate! Coordinate where the output is going to be stored.
Factory employees begin setting up inter-process stores

20. 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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Filming someone with a light on their finger so you can see the movements to better improve the design.
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.

21. What is level three of key 8?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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.
Factory employees begin setting up inter-process stores

22. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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
Morning pep talk meetings are held everyday

23. What is level three of key 5?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Factory employees begin setting up inter-process stores
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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.

24. What is level two of key 8?
Time it takes to make one unit
Supervisors meet to work out time control issues
Video tape a person doing this so they can review what they're doing and improve.
Emphasize the connections between processes and full employee participation in improvement making

25. What does kanban do?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Workers are conscientious about sticking to the work throughout the designated working areas.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

26. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Double capacity and the per unit production cost is 60% of the lower capacity option.
Contamination - inadequate lubrication - misoperation

27. What is level 4 of key 10?
Workers are conscientious about sticking to the work throughout the designated working areas.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
All machines can operate during lunch without monitoring and many operators can handle two or more 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.

28. What is level three of key 6?
Machines work together to prevent overproduction - it stops once it meets demands.
Each section does its own thing; each workplace functions independently
Anyone could find any file within one minute.
People have learned how to make systematic improvements at each process.

29. What is key #5?
Quick changeover technology
Time it takes to make one unit
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'.
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

30. What is level 4 of key 9?
Cycle time - work sequence - standard inventory
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

31. What is key #6?
Everyone recognizes that monitoring is waste
Coupled manufacturing
Manufacturing value analysis
Made the basic elements of human motion (therbligs)

32. What is the order processing and distribution loops?

33. What is level five of key 5?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Doubling productivity - Productivity = Output / TEE
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

34. What are the benefits of quick changeover for companies?
Supervisors meet to work out time control issues
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.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

35. What are the benefits of properly maintaining equipment?
Hands-on activity based on the facts - not opinion.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
You want to equalize your work loads in terms of your lot size - one-piece flow.

36. What is multi-process handling?
Contamination - inadequate lubrication - misoperation
One operator handling several machines or processes
Time it takes to make one unit
Filming someone with a light on their finger so you can see the movements to better improve the design.

37. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Large scale improvement
Quick changeover studies begin; some employees are learning how to implement single changeover.

38. What is key #8?
Coupled manufacturing
Industrial engineering methodologies
Identifying problems before they cause breakdowns.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation

39. What is focused improvement?

40. What is takt time?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
The available production time divided by the rate of customer demand
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.
There is a shotgun approach to improvements; people have little concern for improving methods.

41. What is level two of key 7?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Operators know they must keep their machines in good condition and eliminate the three evils.
Everyone recognizes that monitoring is waste

42. What is level three of key 7?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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
Workers are conscientious about sticking to the work throughout the designated working areas.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

43. What is level four of key 8?
Knowledge - Job security - Safety - Simplicity
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Time it takes to make one unit

44. What is production leveling?
Manufacturing value analysis
Identifying problems before they cause breakdowns.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

45. What is cycle time?
The customer's order starts the process
Time it takes to make one unit
Morning pep talk meetings are held everyday
You want to equalize your work loads in terms of your lot size - one-piece flow.

46. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
All machines can operate during lunch without monitoring and many operators can handle two or more machines

47. 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.
Involving production employees in the total machine maintenance process.
Eliminate certain processes that produce or create waste.
Knowledge - Job security - Safety - Simplicity

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

49. What is level five of key 8?
The available production time divided by the rate of customer demand
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
It's hard because it deals with attitudes of employees.
Helps you understand the facts as they are.

50. What are the three elements of the standard work sheet?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
You want to equalize your work loads in terms of your lot size - one-piece flow.
Cycle time - work sequence - standard inventory
One operator handling several machines or processes