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 four of key 8?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Study the movement and motions of a worker or associate
Eliminate certain processes that produce or create waste.


2. What is the purpose of Chronocyclegraphic analysis?
Operators know they must keep their machines in good condition and eliminate the three evils.
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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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 level one of key 5?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Machines work together to prevent overproduction - it stops once it meets demands.
Continuous improvement of person and process
Time control and commitment


4. What are the 6 Big Losses of TPM?
Eliminate certain processes that produce or create waste.
Hands-on activity based on the facts - not opinion.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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


5. What is the purpose of Cyclegraphic analysis?
Identifying problems before they cause breakdowns.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Filming someone with a light on their finger so you can see the movements to better improve the design.
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 level five of key 6?
Backorders create complacency.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Everyone recognizes that monitoring is waste
Coupled manufacturing


7. What is level four of key 7?
Emphasize the connections between processes and full employee participation in improvement making
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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.
Anyone could find any file within one minute.


8. What is kaizen?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Continuous improvement of person and process
Coupled manufacturing
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary


9. What appears to be the primary metric in key 6?
Determining the life expectancy of components in order to replace them at the optimum time.
Time measuring
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Zero monitor manufacturing


10. What is the purpose of video analysis?

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11. 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.
Work and break times are left to the workers' discretion
Workers are conscientious about sticking to the work throughout the designated working areas.
Study the movement and motions of a worker or associate


12. What are the motions that slow down Type 1 motions?
Study the movement and motions of a worker or associate
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.
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


13. What is the order processing and distribution loops?

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14. What is focused improvement?

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15. What is level 1 of key 9?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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.
Morning pep talk meetings are held everyday
Run the machines into the ground


16. What is level two of key 7?
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
Everyone recognizes that monitoring is waste
Quick changeover studies begin; some employees are learning how to implement single changeover.
You want to equalize your work loads in terms of your lot size - one-piece flow.


17. What is level 3 of key 10?
Supervisors meet to work out time control issues
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
Can be done while the machine is still processing.
Involving production employees in the total machine maintenance process.


18. What is level one of key 7?
Prevents equipment from breaking down or malfunctioning.
No one realizes that monitoring is waste - not work
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


19. What is key #9?
Maintaining equipment
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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.


20. What did Frank Gilbreth do?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Workers are conscientious about sticking to the work throughout the designated working areas.
Made the basic elements of human motion (therbligs)
It's hard because it deals with attitudes of employees.


21. What are the benefits of quick changeover for associates?
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
Executives do not understand the high rate of return linked to integrated improvement.
Knowledge - Job security - Safety - Simplicity
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


22. What is product flow charting?
Time control and commitment
Study the flow of a product through the various operations
Operators know they must keep their machines in good condition and eliminate the three evils.
It's hard because it deals with attitudes of employees.


23. What are the 5 pillars of TPM?

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24. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


25. What is the new product introduction loop?

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26. What is the trouble with large-lot production?
Quick changeover technology
Inventory waste - Delay - Declining quality
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Graphically capturing the steps in a process - Flowcharts with built-in intelligence


27. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
Inventory waste - Delay - Declining quality
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
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)


28. What is the 'Six-Tenths Rule'?
To eliminate the big 3.
Double capacity and the per unit production cost is 60% of the lower capacity option.
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


29. What are the five components of TPM?
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.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Staying competitive with yesterday's products is difficult - if not impossible.


30. What is single file retrieval?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Anyone could find any file within one minute.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect


31. What is level three of key 7?
To eliminate the big 3.
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
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
Hands-on activity based on the facts - not opinion.


32. What does TPM do?
Operators know they must keep their machines in good condition and eliminate the three evils.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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
Prevents equipment from breaking down or malfunctioning.


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

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34. What are the different types of motions required for performing an operation? (Type 1 motions)
There is a shotgun approach to improvements; people have little concern for improving methods.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Coupled manufacturing


35. What are the three evils?
Staying competitive with yesterday's products is difficult - if not impossible.
Contamination - inadequate lubrication - misoperation
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


36. What are the three key technical activities in a TPM program?
Preventative maintenance - Prevention maintenance - Corrective prevention
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Time measuring
Zero monitor manufacturing


37. What is preventative maintenance?
Identifying problems before they cause breakdowns.
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
One operator handling several machines or processes
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


38. What are the flowcharting rules of construction?
Zero monitor manufacturing
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Anyone could find any file within one minute.
Time measuring


39. What is level 2 of key 10?
Manufacturing value analysis
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Morning pep talk meetings are held everyday
Zero monitor manufacturing


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

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41. What are the benefits of properly maintaining equipment?
Work and break times are left to the workers' discretion
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
It's hard because it deals with attitudes of employees.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.


42. What is level 3 of key 9?
Operators know they must keep their machines in good condition and eliminate the three evils.
Machines work together to prevent overproduction - it stops once it meets demands.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.


43. What has to be done to get to level two of key 8?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Supervisors meet to work out time control issues
Eliminate certain processes that produce or create waste.
You have to communicate! Coordinate where the output is going to be stored.


44. What is key 10?
Eliminate certain processes that produce or create waste.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
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 control and commitment


45. What is level one of key 6?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
There is a shotgun approach to improvements; people have little concern for improving methods.
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 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'.


46. 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.
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
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.
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


47. What is the purpose of Therblig analysis?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Double capacity and the per unit production cost is 60% of the lower capacity option.
Helps you understand the facts as they are.
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)


48. What is level one of key 8?
Each section does its own thing; each workplace functions independently
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Time measuring
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs


49. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Identifying problems before they cause breakdowns.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Each section does its own thing; each workplace functions independently


50. What is the value of TPM?
Helps you understand the facts as they are.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
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.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.