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 1 of key 10?

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2. What is an internal setup element?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Can only be done when the machine is stopped or shut down.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Involving production employees in the total machine maintenance process.


3. What is the trouble with large-lot production?
Time measuring
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Determining the life expectancy of components in order to replace them at the optimum time.
Inventory waste - Delay - Declining quality


4. What is level four of key 7?
Can only be done when the machine is stopped or shut down.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Time measuring


5. What are the three elements of the standard work sheet?
Manufacturing value analysis
Each section does its own thing; each workplace functions independently
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.
Cycle time - work sequence - standard inventory


6. What is an external setup element?
Can be done while the machine is still processing.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Time it takes to make one unit
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


7. What are the flowcharting rules of construction?
Factory employees begin setting up inter-process stores
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Doubling productivity - Productivity = Output / TEE
Time it takes to make one unit


8. What is product flow charting?
Knowledge - Job security - Safety - Simplicity
Study the flow of a product through the various operations
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Maintaining equipment


9. What is level three of key 8?
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 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
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'.
Factory employees begin setting up inter-process stores


10. What is the purpose of flowcharting?
Study the movement and motions of a worker or associate
Workers are conscientious about sticking to the work throughout the designated working areas.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Continuous improvement of person and process


11. What is preventative maintenance?
Identifying problems before they cause breakdowns.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Determining the life expectancy of components in order to replace them at the optimum time.
There is a shotgun approach to improvements; people have little concern for improving methods.


12. What appears to be the primary metric in key 6?
Time measuring
One operator handling several machines or processes
Video tape a person doing this so they can review what they're doing and improve.
Work and break times are left to the workers' discretion


13. What is level 1 of key 9?
It's hard because it deals with attitudes of employees.
Study the movement and motions of a worker or associate
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.


14. What does manufacturing value analysis do?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Backorders create complacency.
Factory employees begin setting up inter-process stores
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


15. What is operator flow charting?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Study the movement and motions of a worker or associate
Zero monitor manufacturing
Anyone could find any file within one minute.


16. What is level one of key 7?
No one realizes that monitoring is waste - not work
Can only be done when the machine is stopped or shut down.
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.
Filming someone with a light on their finger so you can see the movements to better improve the design.


17. What is the new product introduction loop?

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18. What is full work system?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Supervisors meet to work out time control issues
Backorders create complacency.
Machines work together to prevent overproduction - it stops once it meets demands.


19. What is level two of key 5?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Quick changeover studies begin; some employees are learning how to implement single changeover.


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

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21. What is level four of key 5?
The customer's order starts the process
Emphasize the connections between processes and full employee participation in improvement making
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.


22. What is the order processing and distribution loops?

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23. What is level three of key 7?
Eliminate certain processes that produce or create waste.
Made the basic elements of human motion (therbligs)
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
Operators know they must keep their machines in good condition and eliminate the three evils.


24. What is key #9?
Staying competitive with yesterday's products is difficult - if not impossible.
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
Maintaining equipment
Operators know they must keep their machines in good condition and eliminate the three evils.


25. What is cycle time?
Time it takes to make one unit
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
Everyone understands the need for PM; PM has been implemented for the most important machines.
Helps you understand the facts as they are.


26. What does kanban do?
Prevents equipment from breaking down or malfunctioning.
Determining the life expectancy of components in order to replace them at the optimum time.
Made the basic elements of human motion (therbligs)
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


27. What is the strategic business development loop?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
To eliminate the big 3.
Executives do not understand the high rate of return linked to integrated improvement.
Each section does its own thing; each workplace functions independently


28. What are the three key technical activities in a TPM program?
Run the machines into the ground
Time control and commitment
Preventative maintenance - Prevention maintenance - Corrective prevention
Maintain normal conditions - early discovery of abnormalities - and prompt response.


29. What are the steps in motion study?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Involving production employees in the total machine maintenance process.
Machines work together to prevent overproduction - it stops once it meets demands.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


30. What is key #5?
Quick changeover technology
Machines work together to prevent overproduction - it stops once it meets demands.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


31. What is focused improvement?

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32. What is level one of key 8?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Each section does its own thing; each workplace functions independently
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
Zero monitor manufacturing


33. What is level one of key 6?
Executives do not understand the high rate of return linked to integrated improvement.
Run the machines into the ground
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)
There is a shotgun approach to improvements; people have little concern for improving methods.


34. What is single file retrieval?
Anyone could find any file within one minute.
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
Time it takes to make one unit
Can only be done when the machine is stopped or shut down.


35. What is the make/ship loop?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Zero monitor manufacturing
Backorders create complacency.


36. What is push production?

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37. What is level five of key 6?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Zero monitor manufacturing
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.


38. What is level four of key 8?
Made the basic elements of human motion (therbligs)
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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


39. What are the benefits of quick changeover for associates?
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
Study the flow of a product through the various operations
Knowledge - Job security - Safety - Simplicity
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


40. At level three of key 6 - what is the methodology employees have been trained to use?
Anyone could find any file within one minute.
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
Industrial engineering methodologies
One operator handling several machines or processes


41. What is the purpose of Therblig analysis?
Helps you understand the facts as they are.
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
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


42. What is level two of key 7?
Everyone recognizes that monitoring is waste
Contamination - inadequate lubrication - misoperation
Time measuring
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


43. What are the three evils?
Contamination - inadequate lubrication - misoperation
Can only be done when the machine is stopped or shut down.
Run the machines into the ground
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


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.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Study the movement and motions of a worker or associate
Hands-on activity based on the facts - not opinion.


45. What is level two of key 8?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Industrial engineering methodologies
Emphasize the connections between processes and full employee participation in improvement making


46. What is level one of key 5?
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.
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
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


47. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
Identifying problems before they cause breakdowns.
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
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


48. What is takt time?
To eliminate the big 3.
Doubling productivity - Productivity = Output / TEE
The available production time divided by the rate of customer demand
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


49. What is the value of TPM?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
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.
Helps you understand the facts as they are.
Continuous improvement of person and process


50. What is corrective maintenance?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Operators know they must keep their machines in good condition and eliminate the three evils.
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.