Test your basic knowledge |

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 are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
To eliminate the big 3.
Everyone recognizes that monitoring is waste
No one realizes that monitoring is waste - not work

2. What is level 5 of key 9?
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

3. Full work systems
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
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
Made the basic elements of human motion (therbligs)
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 level 2 of key 9?
It's hard because it deals with attitudes of employees.
Made the basic elements of human motion (therbligs)
Everyone understands the need for PM; PM has been implemented for the most important machines.
Filming someone with a light on their finger so you can see the movements to better improve the design.

5. What is level 1 of key 9?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
There is a shotgun approach to improvements; people have little concern for improving methods.
Run the machines into the ground
Study the flow of a product through the various operations

6. What is level four of key 5?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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

7. What is level one of key 6?
Study the movement and motions of a worker or associate
Everyone understands the need for PM; PM has been implemented for the most important machines.
Backorders create complacency.
There is a shotgun approach to improvements; people have little concern for improving methods.

8. What are the process improvement steps?
People have learned how to make systematic improvements at each process.
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
You have to communicate! Coordinate where the output is going to be stored.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

9. What are the three evils?
No one realizes that monitoring is waste - not work
Contamination - inadequate lubrication - misoperation
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
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

10. What is autonomous maintenance?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Can be done while the machine is still processing.
Involving production employees in the total machine maintenance process.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

11. What is level 3 of key 9?
Everyone recognizes that monitoring is waste
Operators know they must keep their machines in good condition and eliminate the three evils.
Video tape a person doing this so they can review what they're doing and improve.
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

12. What is level five of key 8?
Determining the life expectancy of components in order to replace them at the optimum 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.
No one realizes that monitoring is waste - not work
Backorders create complacency.

13. What is level three of key 8?
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.
Inventory waste - Delay - Declining quality
Factory employees begin setting up inter-process stores
Continuous improvement of person and process

14. What is pull production?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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 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

15. What has to be done to get to level two of key 8?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
You have to communicate! Coordinate where the output is going to be stored.
Inventory waste - Delay - Declining quality
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

16. What are the different types of motions required for performing an operation? (Type 1 motions)
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Work and break times are left to the workers' discretion
Identifying problems before they cause breakdowns.
Can only be done when the machine is stopped or shut down.

17. What is level four of key 6?
Eliminate certain processes that produce or create waste.
Doubling productivity - Productivity = Output / TEE
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Time it takes to make one unit

18. What is push production?

19. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Doubling productivity - Productivity = Output / TEE
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

20. What is operator flow charting?
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
Study the movement and motions of a worker or associate
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.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

21. What is kaizen?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Continuous improvement of person and process
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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.

22. What is level two of key 5?
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)
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.
Quick changeover studies begin; some employees are learning how to implement single changeover.
People have learned how to make systematic improvements at each process.

23. What is the order processing and distribution loops?

24. What is the main goal of MVA?
Knowledge - Job security - Safety - Simplicity
Doubling productivity - Productivity = Output / TEE
The customer's order starts the process
Made the basic elements of human motion (therbligs)

25. What is the goal of motion study?
Made the basic elements of human motion (therbligs)
Can be done while the machine is still processing.
To eliminate the big 3.
Preventative maintenance - Prevention maintenance - Corrective prevention

26. What is level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Everyone recognizes that monitoring is waste
No one realizes that monitoring is waste - not work
Maintaining equipment

27. What is cycle time?
Prevents equipment from breaking down or malfunctioning.
People have learned how to make systematic improvements at each process.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Time it takes to make one unit

28. What is level three of key 7?
Can only be done when the machine is stopped or shut down.
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
Video tape a person doing this so they can review what they're doing and improve.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

29. What appears to be the primary metric in key 6?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Time measuring
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Maintaining equipment

30. What are the basic steps in a traditional changeover?
Workers are conscientious about sticking to the work throughout the designated working areas.
Study the flow of a product through the various operations
Determining the life expectancy of components in order to replace them at the optimum time.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

31. What does manufacturing value analysis do?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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
Time measuring
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

32. What is level 4 of key 9?
Can be done while the machine is still processing.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

33. What does kanban 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
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Prevents equipment from breaking down or malfunctioning.
Can be done while the machine is still processing.

34. 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
Filming someone with a light on their finger so you can see the movements to better improve the design.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

35. What is level five of key 5?
Workers are conscientious about sticking to the work throughout the designated working areas.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Large scale improvement

36. What is focused improvement?

37. What are the benefits of quick changeover for companies?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Workers are conscientious about sticking to the work throughout the designated working areas.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

38. What are the motions that do not perform an operation?
Knowledge - Job security - Safety - Simplicity
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

39. What is level three of key 5?
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
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'.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

40. What is the strategic business development loop?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Helps you understand the facts as they are.
Executives do not understand the high rate of return linked to integrated improvement.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

41. What is level three of key 6?
To eliminate the big 3.
People have learned how to make systematic improvements at each process.
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.
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

42. What is level 4 of key 10?
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
Workers are conscientious about sticking to the work throughout the designated working areas.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
You want to equalize your work loads in terms of your lot size - one-piece flow.

43. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
There is a shotgun approach to improvements; people have little concern for improving methods.
Study the flow of a product through the various operations
Involving production employees in the total machine maintenance process.

44. What is an external setup element?
The available production time divided by the rate of customer demand
Can be done while the machine is still processing.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

45. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
The available production time divided by the rate of customer demand
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Hands-on activity based on the facts - not opinion.

46. What is the new product introduction loop?

47. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
Backorders create complacency.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Cycle time - work sequence - standard inventory

48. What is kaikaku?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Everyone recognizes that monitoring is waste
Morning pep talk meetings are held everyday
Large scale improvement

49. What is multi-process handling?
The customer's order starts the process
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Time control and commitment
One operator handling several machines or processes

50. What is key #6?
Manufacturing value analysis
Involving production employees in the total machine maintenance process.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Zero monitor manufacturing