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 different types of motions required for performing an operation? (Type 1 motions)
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Factory employees begin setting up inter-process stores
Workers are conscientious about sticking to the work throughout the designated working areas.

2. What is key #6?
There is a shotgun approach to improvements; people have little concern for improving methods.
Determining the life expectancy of components in order to replace them at the optimum time.
Inventory waste - Delay - Declining quality
Manufacturing value analysis

3. What is preventive maintenance?
Time control and commitment
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Each section does its own thing; each workplace functions independently

4. What is the 'Six-Tenths Rule'?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Zero monitor manufacturing
Determining the life expectancy of components in order to replace them at the optimum time.
Double capacity and the per unit production cost is 60% of the lower capacity option.

5. What is the purpose of Therblig analysis?
Helps you understand the facts as they are.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Backorders create complacency.
Cycle time - work sequence - standard inventory

6. What are the five components of TPM?
Time it takes to make one unit
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
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
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

7. What is the goal of motion study?
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.
To eliminate the big 3.
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)

8. What is multi-process handling?
Prevents equipment from breaking down or malfunctioning.
Factory employees begin setting up inter-process stores
One operator handling several machines or processes
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.

9. What is full work system?
Knowledge - Job security - Safety - Simplicity
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Machines work together to prevent overproduction - it stops once it meets demands.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

10. What is predictive maintenance?
Zero monitor manufacturing
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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)

11. What are the steps in motion study?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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)

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

13. 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
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Maintaining equipment
Zero monitor manufacturing

14. What has to be done to get to level two of key 8?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
You have to communicate! Coordinate where the output is going to be stored.

15. What is level one of key 8?
You have to communicate! Coordinate where the output is going to be stored.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
You want to equalize your work loads in terms of your lot size - one-piece flow.
Each section does its own thing; each workplace functions independently

16. What is level three of key 7?
Double capacity and the per unit production cost is 60% of the lower capacity option.
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
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

17. What is takt time?
Industrial engineering methodologies
The available production time divided by the rate of customer demand
Knowledge - Job security - Safety - Simplicity
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

18. What is autonomous maintenance?
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.
Workers are conscientious about sticking to the work throughout the designated working areas.
Everyone understands the need for PM; PM has been implemented for the most important machines.

19. What are the process improvement steps?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Cycle time - work sequence - standard inventory
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

20. What are the three evils?
Executives do not understand the high rate of return linked to integrated improvement.
Contamination - inadequate lubrication - misoperation
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.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

21. What is level 2 of key 9?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Everyone understands the need for PM; PM has been implemented for the most important machines.
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.
Time control and commitment

22. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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.
Double capacity and the per unit production cost is 60% of the lower capacity option.

23. What is key #9?
Maintaining equipment
Manufacturing value analysis
Continuous improvement of person and process
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

24. At level three of key 6 - what is the methodology employees have been trained to use?
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.
Industrial engineering methodologies
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
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

25. What is level four of key 6?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Quick changeover technology
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
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

26. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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 that blinks at a pre-determined interval so you can see the movements to better improve the design.

27. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Run the machines into the ground
To eliminate the big 3.

28. What is level 5 of key 9?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
People have learned how to make systematic improvements at each process.
Supervisors meet to work out time control issues
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'.

29. What is key 10?
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
Determining the life expectancy of components in order to replace them at the optimum time.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Time control and commitment

30. What is prevention maintenance?
Morning pep talk meetings are held everyday
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Continuous improvement of person and process
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

31. What is product flow charting?
The available production time divided by the rate of customer demand
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
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

32. What are the steps in Shingo's changeover system?
Identifying problems before they cause breakdowns.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Preventative maintenance - Prevention maintenance - Corrective prevention
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

33. What is the strategic business development loop?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Executives do not understand the high rate of return linked to integrated improvement.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Anyone could find any file within one minute.

34. What is key #8?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Coupled manufacturing
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence

35. What is cycle time?
Morning pep talk meetings are held everyday
Time it takes to make one unit
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.
Everyone understands the need for PM; PM has been implemented for the most important machines.

36. What is key #5?
Quick changeover technology
Manufacturing value analysis
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.
Continuous improvement of person and process

37. What is level four of key 8?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
You have to communicate! Coordinate where the output is going to be stored.
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.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

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

39. What did Frank Gilbreth do?
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
Large scale improvement
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
Made the basic elements of human motion (therbligs)

40. What does TPM do?
Run the machines into the ground
Executives do not understand the high rate of return linked to integrated improvement.
Prevents equipment from breaking down or malfunctioning.
It's hard because it deals with attitudes of employees.

41. What is level 1 of key 9?
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
Run the machines into the ground
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 it takes to make one unit

42. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
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.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

43. What is level three of key 8?
Factory employees begin setting up inter-process stores
Can only be done when the machine is stopped or shut down.
Study the flow of a product through the various operations
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

44. What is level five of key 8?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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.

45. What is the purpose of Chronocyclegraphic analysis?
Industrial engineering methodologies
Double capacity and the per unit production cost is 60% of the lower capacity option.
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.
To eliminate the big 3.

46. What is the make/ship loop?
You have to communicate! Coordinate where the output is going to be stored.
Backorders create complacency.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

47. What is autonomation (Jidoka)?
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
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Filming someone with a light on their finger so you can see the movements to better improve the design.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

48. What are the benefits of properly maintaining equipment?
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

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

50. What is key #7?
Executives do not understand the high rate of return linked to integrated improvement.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Zero monitor manufacturing
Double capacity and the per unit production cost is 60% of the lower capacity option.