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 the strategic business development loop?
Executives do not understand the high rate of return linked to integrated improvement.
Time it takes to make one unit
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'.


2. What is autonomous maintenance?
Involving production employees in the total machine maintenance process.
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
Preventative maintenance - Prevention maintenance - Corrective prevention
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.


3. What are the flowcharting rules of construction?
Time measuring
Large scale improvement
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.


4. What is single file retrieval?
Morning pep talk meetings are held everyday
Time measuring
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.


5. What appears to be the primary metric in key 6?
Time measuring
Quick changeover studies begin; some employees are learning how to implement single changeover.
Operators know they must keep their machines in good condition and eliminate the three evils.
You have to communicate! Coordinate where the output is going to be stored.


6. What is level three of key 8?
Factory employees begin setting up inter-process stores
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Video tape a person doing this so they can review what they're doing and improve.
Industrial engineering methodologies


7. What is the 'Six-Tenths Rule'?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Cycle time - work sequence - standard inventory
People have learned how to make systematic improvements at each process.


8. What is the order processing and distribution loops?

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9. Full work systems
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
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
Machines work together to prevent overproduction - it stops once it meets demands.
Video tape a person doing this so they can review what they're doing and improve.


10. What are the steps in motion study?
Executives do not understand the high rate of return linked to integrated improvement.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Morning pep talk meetings are held everyday
Knowledge - Job security - Safety - Simplicity


11. What is pull production?
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
Maintaining equipment
Hands-on activity based on the facts - not opinion.
Factory employees begin setting up inter-process stores


12. What is level four of key 5?
Time it takes to make one unit
Executives do not understand the high rate of return linked to integrated improvement.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Industrial engineering methodologies


13. What is kaikaku?
Knowledge - Job security - Safety - Simplicity
Time measuring
Can only be done when the machine is stopped or shut down.
Large scale improvement


14. What is level five of key 6?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Everyone recognizes that monitoring is waste
Time measuring
Knowledge - Job security - Safety - Simplicity


15. 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.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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.


16. What is takt time?
No one realizes that monitoring is waste - not work
Inventory waste - Delay - Declining quality
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)
The available production time divided by the rate of customer demand


17. What is an external setup element?
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
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Can be done while the machine is still processing.


18. What is the trouble with large-lot production?
Inventory waste - Delay - Declining quality
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Anyone could find any file within one minute.
Morning pep talk meetings are held everyday


19. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
To eliminate the big 3.
Quick changeover technology


20. At level three of key 6 - what is the methodology employees have been trained to use?
Industrial engineering methodologies
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Everyone recognizes that monitoring is waste
Run the machines into the ground


21. What does kanban do?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Contamination - inadequate lubrication - misoperation


22. What is level two of key 5?
Everyone recognizes that monitoring is waste
Continuous improvement of person and process
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.


23. What does TPM do?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
You have to communicate! Coordinate where the output is going to be stored.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Prevents equipment from breaking down or malfunctioning.


24. What are the motions that do not perform an operation?
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.
Contamination - inadequate lubrication - misoperation
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
People have learned how to make systematic improvements at each process.


25. What are the 5 pillars of TPM?

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26. What is an internal setup element?
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
Operators know they must keep their machines in good condition and eliminate the three evils.
Can only be done when the machine is stopped or shut down.


27. What is the purpose of flowcharting?
Manufacturing value analysis
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


28. What are the motions that slow down Type 1 motions?
You have to communicate! Coordinate where the output is going to be stored.
Large scale improvement
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)
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.


29. What is level 3 of key 9?
Preventative maintenance - Prevention maintenance - Corrective prevention
Operators know they must keep their machines in good condition and eliminate the three evils.
You have to communicate! Coordinate where the output is going to be stored.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


30. What is level two of key 7?
Cycle time - work sequence - standard inventory
Everyone recognizes that monitoring is waste
Filming someone with a light on their finger so you can see the movements to better improve the design.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.


31. What is level three of key 6?
People have learned how to make systematic improvements at each process.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


32. What is level 4 of key 9?
Preventative maintenance - Prevention maintenance - Corrective prevention
Executives do not understand the high rate of return linked to integrated improvement.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


33. What is corrective maintenance?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Eliminate certain processes that produce or create waste.
Continuous improvement of person and process
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.


34. What is the goal of motion study?
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
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
To eliminate the big 3.
Run the machines into the ground


35. What is the new product introduction loop?

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36. What is level one of key 7?
Zero monitor manufacturing
No one realizes that monitoring is waste - not work
All machines can operate during lunch without monitoring and many operators can handle two or more machines
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


37. What are the functions and rules of kanban?
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 movement and motions of a worker or associate
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Executives do not understand the high rate of return linked to integrated improvement.


38. What is level 1 of key 9?
Determining the life expectancy of components in order to replace them at the optimum time.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Time it takes to make one unit
Run the machines into the ground


39. 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
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Prevents equipment from breaking down or malfunctioning.
Knowledge - Job security - Safety - Simplicity


40. What are the benefits of quick changeover for associates?
There is a shotgun approach to improvements; people have little concern for improving methods.
Knowledge - Job security - Safety - Simplicity
Morning pep talk meetings are held everyday
Each section does its own thing; each workplace functions independently


41. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Knowledge - Job security - Safety - Simplicity
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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'.


42. What did Frank Gilbreth do?
Contamination - inadequate lubrication - misoperation
Made the basic elements of human motion (therbligs)
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.
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'.


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

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44. What is level five 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.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
There is a shotgun approach to improvements; people have little concern for improving methods.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


45. What is Industrial Engineering?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Can be done while the machine is still processing.
Hands-on activity based on the facts - not opinion.


46. What is prevention maintenance?
Hands-on activity based on the facts - not opinion.
Supervisors meet to work out time control issues
Contamination - inadequate lubrication - misoperation
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


47. What is the purpose of Chronocyclegraphic analysis?
Study the movement and motions of a worker or associate
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
Inventory waste - Delay - Declining quality


48. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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
Run the machines into the ground


49. What is kaizen?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Staying competitive with yesterday's products is difficult - if not impossible.
Factory employees begin setting up inter-process stores
Continuous improvement of person and process


50. What is push production?

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