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 2 of key 10?
Morning pep talk meetings are held everyday
Work and break times are left to the workers' discretion
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Quick changeover technology


2. What is the new product introduction loop?

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3. What is pull production?
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
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
You have to communicate! Coordinate where the output is going to be stored.


4. What is level five of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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


5. What are the flowcharting rules of construction?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Determining the life expectancy of components in order to replace them at the optimum time.


6. What are the five components of TPM?
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
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Maintaining equipment
Study the flow of a product through the various operations


7. What is level two of key 7?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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
The available production time divided by the rate of customer demand
Everyone recognizes that monitoring is waste


8. What is predictive maintenance?
Supervisors meet to work out time control issues
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Large scale improvement
Determining the life expectancy of components in order to replace them at the optimum time.


9. What is level four of key 6?
Everyone recognizes that monitoring is waste
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


10. What is level 1 of key 10?

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11. What is autonomous maintenance?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Involving production employees in the total machine maintenance process.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


12. What are the benefits of quick changeover for associates?
To eliminate the big 3.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Knowledge - Job security - Safety - Simplicity
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


13. What is the purpose of Cyclegraphic analysis?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Supervisors meet to work out time control issues
You want to equalize your work loads in terms of your lot size - one-piece flow.


14. What is level two of key 8?
Morning pep talk meetings are held everyday
Emphasize the connections between processes and full employee participation in improvement making
You have to communicate! Coordinate where the output is going to be stored.
Each section does its own thing; each workplace functions independently


15. What is level five of key 6?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Supervisors meet to work out time control issues
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


16. What is key 10?
Continuous improvement of person and process
Time control and commitment
Anyone could find any file within one minute.
Morning pep talk meetings are held everyday


17. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Large scale improvement
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


18. What are the different types of motions required for performing an operation? (Type 1 motions)
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Run the machines into the ground
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


19. 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.
Zero monitor manufacturing
You want to equalize your work loads in terms of your lot size - one-piece flow.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.


20. What is the order processing and distribution loops?

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21. What is focused improvement?

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22. What is the purpose of Chronocyclegraphic analysis?
Factory employees begin setting up inter-process stores
Supervisors meet to work out time control issues
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.
Helps you understand the facts as they are.


23. What is an external setup element?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Manufacturing value analysis
Emphasize the connections between processes and full employee participation in improvement making
Can be done while the machine is still processing.


24. What are the functions and rules of kanban?
To eliminate the big 3.
One operator handling several machines or processes
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 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


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

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26. What are the 6 Big Losses of TPM?
Backorders create complacency.
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
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.


27. What does kanban do?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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.
Determining the life expectancy of components in order to replace them at the optimum time.


28. What is level one of key 5?
There is a shotgun approach to improvements; people have little concern for improving methods.
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.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.


29. What are the 5 pillars of TPM?

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30. What is the purpose of operator flow charting?
Eliminate certain processes that produce or create waste.
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)
Hands-on activity based on the facts - not opinion.
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


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

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32. What is key #6?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Manufacturing value analysis
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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


33. What is level one of key 8?
One operator handling several machines or processes
Each section does its own thing; each workplace functions independently
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


34. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Manufacturing value analysis
Time measuring
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.


35. What is level 2 of key 9?
Can only be done when the machine is stopped or shut down.
Everyone understands the need for PM; PM has been implemented for the most important machines.
Prevents equipment from breaking down or malfunctioning.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.


36. What are the steps in Shingo's changeover system?
Machines work together to prevent overproduction - it stops once it meets demands.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


37. What are the benefits of quick changeover for companies?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
It's hard because it deals with attitudes of employees.
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 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


38. What is level three 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.
Emphasize the connections between processes and full employee participation in improvement making
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
You have to communicate! Coordinate where the output is going to be stored.


39. What is full work system?
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
Machines work together to prevent overproduction - it stops once it meets demands.
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
To eliminate the big 3.


40. What are the three elements of the standard work sheet?
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.
Everyone recognizes that monitoring is waste
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Cycle time - work sequence - standard inventory


41. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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 only be done when the machine is stopped or shut down.


42. What is kaizen?
You have to communicate! Coordinate where the output is going to be stored.
Continuous improvement of person and process
People have learned how to make systematic improvements at each process.
Involving production employees in the total machine maintenance process.


43. What are the three key technical activities in a TPM program?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
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
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Preventative maintenance - Prevention maintenance - Corrective prevention


44. What is preventative maintenance?
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
Identifying problems before they cause breakdowns.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
It's hard because it deals with attitudes of employees.


45. What is level four of key 5?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Factory employees begin setting up inter-process stores
Eliminate certain processes that produce or create waste.
Helps you understand the facts as they are.


46. What is level two of key 5?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Factory employees begin setting up inter-process stores
Quick changeover studies begin; some employees are learning how to implement single changeover.


47. What is level four of key 7?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Time measuring
Large scale improvement
Factory employees begin setting up inter-process stores


48. What appears to be the primary metric in key 6?
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.
Time measuring
There is a shotgun approach to improvements; people have little concern for improving methods.
Preventative maintenance - Prevention maintenance - Corrective prevention


49. What are the three principles of prevention?
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
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
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Knowledge - Job security - Safety - Simplicity


50. What is multi-process handling?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
One operator handling several machines or processes
Machines work together to prevent overproduction - it stops once it meets demands.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.