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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 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
There is a shotgun approach to improvements; people have little concern for improving methods.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
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.

2. What is level five of key 5?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.

3. What is key #8?
Coupled manufacturing
Determining the life expectancy of components in order to replace them at the optimum time.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

4. What has to be done to get to level two of key 8?
You have to communicate! Coordinate where the output is going to be stored.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

5. What is push production?

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6. 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
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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
Study the flow of a product through the various operations

7. What is key 10?
Time control and commitment
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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.

8. What is the trouble with large-lot production?
Inventory waste - Delay - Declining quality
To eliminate the big 3.
Everyone recognizes that monitoring is waste
Hands-on activity based on the facts - not opinion.

9. What are the three pillars of lean systems?
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
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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

10. What is level five of key 8?
Made the basic elements of human motion (therbligs)
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
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

11. What is level four of key 8?
Time measuring
Anyone could find any file within one minute.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

12. What is level 2 of key 9?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Operators know they must keep their machines in good condition and eliminate the three evils.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Factory employees begin setting up inter-process stores

13. What is predictive maintenance?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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)
Eliminate certain processes that produce or create waste.

14. What is level one of key 7?
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.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
No one realizes that monitoring is waste - not work
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

15. What is key #9?
Maintaining equipment
Cycle time - work sequence - standard inventory
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
Morning pep talk meetings are held everyday

16. What is level 3 of key 9?
Can only be done when the machine is stopped or shut down.
Staying competitive with yesterday's products is difficult - if not impossible.
Operators know they must keep their machines in good condition and eliminate the three evils.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

17. What is the 'Six-Tenths Rule'?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Knowledge - Job security - Safety - Simplicity
Inventory waste - Delay - Declining quality
Double capacity and the per unit production cost is 60% of the lower capacity option.

18. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
One operator handling several machines or processes
Industrial engineering methodologies
Everyone understands the need for PM; PM has been implemented for the most important machines.

19. What is full work system?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
The customer's order starts the process
Machines work together to prevent overproduction - it stops once it meets demands.
Can only be done when the machine is stopped or shut down.

20. What is key #7?
Zero monitor manufacturing
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Hands-on activity based on the facts - not opinion.
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

21. What is cycle time?
Continuous improvement of person and process
Time it takes to make one unit
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Double capacity and the per unit production cost is 60% of the lower capacity option.

22. What are the three key technical activities in a TPM program?
Manufacturing value analysis
Operators know they must keep their machines in good condition and eliminate the three evils.
Preventative maintenance - Prevention maintenance - Corrective prevention
Hands-on activity based on the facts - not opinion.

23. What is the new product introduction loop?

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24. What is the value of TPM?
Involving production employees in the total machine maintenance process.
Backorders create complacency.
Made the basic elements of human motion (therbligs)
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.

25. What is preventative maintenance?
Manufacturing value analysis
Eliminate certain processes that produce or create waste.
Identifying problems before they cause breakdowns.
Can only be done when the machine is stopped or shut down.

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

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27. What does manufacturing value analysis do?
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
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
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)
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

28. What is the purpose of Cyclegraphic analysis?
The customer's order starts the process
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.
Filming someone with a light on their finger so you can see the movements to better improve the design.
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

29. What is prevention maintenance?
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
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
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Everyone recognizes that monitoring is waste

30. What is kaizen?
Continuous improvement of person and process
Everyone understands the need for PM; PM has been implemented for the most important machines.
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.
Study the movement and motions of a worker or associate

31. What is level five of key 6?
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.
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
Cycle time - work sequence - standard inventory

32. What does TPM do?
Prevents equipment from breaking down or malfunctioning.
The customer's order starts the process
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Made the basic elements of human motion (therbligs)

33. What is the main goal of MVA?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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.
Doubling productivity - Productivity = Output / TEE
Contamination - inadequate lubrication - misoperation

34. What does kanban do?
Maintaining equipment
Staying competitive with yesterday's products is difficult - if not impossible.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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

35. What is the goal of motion study?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
To eliminate the big 3.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
No one realizes that monitoring is waste - not work

36. What is an external setup element?
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.
Maintaining equipment
Can be done while the machine is still processing.

37. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands the need for PM; PM has been implemented for the most important machines.
Backorders create complacency.
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

38. What is level two of key 6?
Study the flow of a product through the various operations
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Morning pep talk meetings are held everyday
Coupled manufacturing

39. What is an internal setup element?
Can only be done when the machine is stopped or shut down.
Determining the life expectancy of components in order to replace them at the optimum time.
Anyone could find any file within one minute.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

40. What is preventive maintenance?
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.
Time control and commitment
It's hard because it deals with attitudes of employees.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

41. What is production leveling?
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
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Contamination - inadequate lubrication - misoperation

42. What is level four of key 6?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Work and break times are left to the workers' discretion
There is a shotgun approach to improvements; people have little concern for improving methods.
You want to equalize your work loads in terms of your lot size - one-piece flow.

43. 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
Anyone could find any file within one minute.
Knowledge - Job security - Safety - Simplicity
There is a shotgun approach to improvements; people have little concern for improving methods.

44. What is level five of key 7?
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
There is a shotgun approach to improvements; people have little concern for improving methods.

45. What is level four of key 5?
Supervisors meet to work out time control issues
Double capacity and the per unit production cost is 60% of the lower capacity option.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

46. What is level two of key 8?
Cycle time - work sequence - standard inventory
Emphasize the connections between processes and full employee participation in improvement making
Eliminate certain processes that produce or create waste.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation

47. What is level three of key 7?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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

48. What are the five components of TPM?
Factory employees begin setting up inter-process stores
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Cycle time - work sequence - standard inventory

49. What is level 2 of key 10?
Morning pep talk meetings are held everyday
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
One operator handling several machines or processes
Maintain normal conditions - early discovery of abnormalities - and prompt response.

50. What is level 4 of key 9?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
People have learned how to make systematic improvements at each process.
To eliminate the big 3.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation