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 three of key 7?
Time control and commitment
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
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
Industrial engineering methodologies


2. What does kanban do?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Can be done while the machine is still processing.
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'.


3. What is pull production?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Video tape a person doing this so they can review what they're doing and improve.
Study the flow of a product through the various operations
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


4. What are the three elements of the standard work sheet?
Determining the life expectancy of components in order to replace them at the optimum time.
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)
Can only be done when the machine is stopped or shut down.
Cycle time - work sequence - standard inventory


5. What is autonomation (Jidoka)?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Quick changeover studies begin; some employees are learning how to implement single changeover.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


6. What is the trouble with large-lot production?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Coupled manufacturing
Inventory waste - Delay - Declining quality
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'.


7. What is autonomous maintenance?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Knowledge - Job security - Safety - Simplicity
Involving production employees in the total machine maintenance process.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.


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

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9. What is the main goal of MVA?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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
Doubling productivity - Productivity = Output / TEE
Coupled manufacturing


10. What is key #8?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Coupled manufacturing
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


11. What is an external setup element?
Executives do not understand the high rate of return linked to integrated improvement.
Can be done while the machine is still processing.
Machines work together to prevent overproduction - it stops once it meets demands.
There is a shotgun approach to improvements; people have little concern for improving methods.


12. What is level two of key 8?
Supervisors meet to work out time control issues
Emphasize the connections between processes and full employee participation in improvement making
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Anyone could find any file within one minute.


13. What are the benefits of quick changeover for associates?
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)
Industrial engineering methodologies
Study the movement and motions of a worker or associate
Knowledge - Job security - Safety - Simplicity


14. What appears to be the primary metric in key 6?
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
Time measuring
Time it takes to make one unit
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


15. What is level two of key 7?
Continuous improvement of person and process
Everyone recognizes that monitoring is waste
Contamination - inadequate lubrication - misoperation
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


16. What are the three pillars of lean systems?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Study the movement and motions of a worker or associate
Industrial engineering methodologies
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


17. What is level four of key 5?
Operators know they must keep their machines in good condition and eliminate the three evils.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Continuous improvement of person and process
Identifying problems before they cause breakdowns.


18. What is Industrial Engineering?
Identifying problems before they cause breakdowns.
Hands-on activity based on the facts - not opinion.
Staying competitive with yesterday's products is difficult - if not impossible.
The available production time divided by the rate of customer demand


19. What is level three of key 5?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Everyone understands the need for PM; PM has been implemented for the most important machines.


20. What is level one of key 5?
Zero monitor manufacturing
Time it takes to make one unit
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Operators know they must keep their machines in good condition and eliminate the three evils.


21. What is the purpose of video analysis?

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22. What is level one of key 7?
Time measuring
No one realizes that monitoring is waste - not work
Executives do not understand the high rate of return linked to integrated improvement.
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.


23. What are the three key technical activities in a TPM program?
Identifying problems before they cause breakdowns.
Cycle time - work sequence - standard inventory
There is a shotgun approach to improvements; people have little concern for improving methods.
Preventative maintenance - Prevention maintenance - Corrective prevention


24. What are the process improvement steps?
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
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
One operator handling several machines or processes
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.


25. What is level five of key 5?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


26. What is key #9?
Hands-on activity based on the facts - not opinion.
Maintaining equipment
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Preventative maintenance - Prevention maintenance - Corrective prevention


27. What are the three evils?
Involving production employees in the total machine maintenance process.
Contamination - inadequate lubrication - misoperation
Prevents equipment from breaking down or malfunctioning.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


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

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29. What is level five of key 6?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Workers are conscientious about sticking to the work throughout the designated working areas.
Staying competitive with yesterday's products is difficult - if not impossible.


30. What is level 4 of key 10?
Made the basic elements of human motion (therbligs)
Continuous improvement of person and process
Filming someone with a light on their finger so you can see the movements to better improve the design.
Workers are conscientious about sticking to the work throughout the designated working areas.


31. What is key #6?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
To eliminate the big 3.
Manufacturing value analysis


32. What is the goal of motion study?
To eliminate the big 3.
Cycle time - work sequence - standard inventory
Zero monitor manufacturing
Helps you understand the facts as they are.


33. What is product flow charting?
Continuous improvement of person and process
Study the flow of a product through the various operations
Factory employees begin setting up inter-process stores
To eliminate the big 3.


34. What is the purpose of Cyclegraphic analysis?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Time control and commitment
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Filming someone with a light on their finger so you can see the movements to better improve the design.


35. What are the functions and rules of kanban?
There is a shotgun approach to improvements; people have little concern for improving methods.
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
Identifying problems before they cause breakdowns.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover


36. What is level 5 of key 10?
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
Quick changeover technology
Made the basic elements of human motion (therbligs)


37. What is level two of key 6?
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
The customer's order starts the process
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Can only be done when the machine is stopped or shut down.


38. What is level one of key 6?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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.
Industrial engineering methodologies


39. What is the purpose of operator flow charting?
Eliminate certain processes that produce or create waste.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
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)
One operator handling several machines or processes


40. What is level 2 of key 9?
Manufacturing value analysis
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Everyone understands the need for PM; PM has been implemented for the most important machines.
You want to equalize your work loads in terms of your lot size - one-piece flow.


41. What is cycle time?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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'.
Time it takes to make one unit
Made the basic elements of human motion (therbligs)


42. What is operator flow charting?
Can only be done when the machine is stopped or shut down.
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Study the movement and motions of a worker or associate


43. What is key #5?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Each section does its own thing; each workplace functions independently
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


44. What is level 1 of key 9?
Run the machines into the ground
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Involving production employees in the total machine maintenance process.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.


45. What does manufacturing value analysis do?
Helps you understand the facts as they are.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
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
One operator handling several machines or processes


46. What is level 1 of key 10?

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47. What is level 4 of key 9?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Involving production employees in the total machine maintenance process.


48. What are the benefits of properly maintaining equipment?
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
Anyone could find any file within one minute.
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.


49. What is the new product introduction loop?

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

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