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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 is prevention maintenance?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

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

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3. What are the three principles of prevention?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

4. At level three of key 6 - what is the methodology employees have been trained to use?
Made the basic elements of human motion (therbligs)
Preventative maintenance - Prevention maintenance - Corrective prevention
Industrial engineering methodologies
Can only be done when the machine is stopped or shut down.

5. Full work systems
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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 controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

6. What are the 6 Big Losses of TPM?
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
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Anyone could find any file within one minute.
Each section does its own thing; each workplace functions independently

7. What is level one of key 5?
Prevents equipment from breaking down or malfunctioning.
Staying competitive with yesterday's products is difficult - if not impossible.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

8. What is key 10?
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
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Time control and commitment
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

9. What is pull production?
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)
Emphasize the connections between processes and full employee participation in improvement making
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.

10. What are the functions and rules of kanban?
Maintaining equipment
Identifying problems before they cause breakdowns.
Study the flow of a product through the various operations
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

11. What is level 1 of key 9?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Large scale improvement
Each section does its own thing; each workplace functions independently
Run the machines into the ground

12. What is an internal setup element?
Maintaining equipment
Everyone understands the need for PM; PM has been implemented for the most important machines.
Can only be done when the machine is stopped or shut down.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

13. What is the strategic business development loop?
Determining the life expectancy of components in order to replace them at the optimum time.
Identifying problems before they cause breakdowns.
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
Executives do not understand the high rate of return linked to integrated improvement.

14. 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
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
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
People have learned how to make systematic improvements at each process.

15. What is level three of key 7?
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
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.

16. What is the goal of motion study?
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)
You want to equalize your work loads in terms of your lot size - one-piece flow.
To eliminate the big 3.

17. What is the purpose of video analysis?

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18. What are the motions that do not perform an operation?
Backorders create complacency.
Zero monitor manufacturing
Prevents equipment from breaking down or malfunctioning.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

19. What is level four of key 5?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Factory employees begin setting up inter-process stores
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Industrial engineering methodologies

20. What is level one of key 6?
Cycle time - work sequence - standard inventory
Quick changeover technology
There is a shotgun approach to improvements; people have little concern for improving methods.
Emphasize the connections between processes and full employee participation in improvement making

21. What is operator flow charting?
Time control and commitment
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
Backorders create complacency.
Study the movement and motions of a worker or associate

22. What does TPM do?
Study the flow of a product through the various operations
Factory employees begin setting up inter-process stores
Prevents equipment from breaking down or malfunctioning.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

23. What is kaikaku?
Continuous improvement of person and process
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Large scale improvement
Preventative maintenance - Prevention maintenance - Corrective prevention

24. What are the motions that slow down Type 1 motions?
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
Quick changeover studies begin; some employees are learning how to implement single changeover.
Doubling productivity - Productivity = Output / TEE
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)

25. What is focused improvement?

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26. What is key #7?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
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'.
Zero monitor manufacturing

27. What are the three key technical activities in a TPM program?
The customer's order starts the process
Executives do not understand the high rate of return linked to integrated improvement.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Preventative maintenance - Prevention maintenance - Corrective prevention

28. What are the benefits of quick changeover for associates?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Knowledge - Job security - Safety - Simplicity
Study the flow of a product through the various operations
Emphasize the connections between processes and full employee participation in improvement making

29. What is key #9?
Maintaining equipment
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Contamination - inadequate lubrication - misoperation
Identifying problems before they cause breakdowns.

30. What are the steps in Shingo's changeover system?
Made the basic elements of human motion (therbligs)
Time measuring
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation

31. What has to be done to get to level two of key 8?
Machines work together to prevent overproduction - it stops once it meets demands.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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
You have to communicate! Coordinate where the output is going to be stored.

32. What is predictive maintenance?
Determining the life expectancy of components in order to replace them at the optimum time.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Study the movement and motions of a worker or associate
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

33. What did Frank Gilbreth do?
Made the basic elements of human motion (therbligs)
Quick changeover technology
Cycle time - work sequence - standard inventory
You want to equalize your work loads in terms of your lot size - one-piece flow.

34. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Work and break times are left to the workers' discretion

35. What is Industrial Engineering?
Work and break times are left to the workers' discretion
Hands-on activity based on the facts - not opinion.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

36. What is level three of key 6?
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
Prevents equipment from breaking down or malfunctioning.
Manufacturing value analysis
People have learned how to make systematic improvements at each process.

37. What is single file retrieval?
Anyone could find any file within one minute.
Coupled manufacturing
Staying competitive with yesterday's products is difficult - if not impossible.
Morning pep talk meetings are held everyday

38. What does manufacturing value analysis do?
Contamination - inadequate lubrication - misoperation
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
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 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

39. What is the purpose of Therblig analysis?
Factory employees begin setting up inter-process stores
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.
Helps you understand the facts as they are.
Operators know they must keep their machines in good condition and eliminate the three evils.

40. What is level five of key 6?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Emphasize the connections between processes and full employee participation in improvement making
Knowledge - Job security - Safety - Simplicity
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.

41. What are the basic steps in a traditional changeover?
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Anyone could find any file within one minute.
Industrial engineering methodologies
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments

42. What is level three of key 5?
Machines work together to prevent overproduction - it stops once it meets demands.
Prevents equipment from breaking down or malfunctioning.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
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

43. What is takt time?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Hands-on activity based on the facts - not opinion.
To eliminate the big 3.
The available production time divided by the rate of customer demand

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

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45. What is the trouble with large-lot production?
Backorders create complacency.
Machines work together to prevent overproduction - it stops once it meets demands.
Inventory waste - Delay - Declining quality
Quick changeover studies begin; some employees are learning how to implement single changeover.

46. What is level 5 of key 10?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
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
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

47. What is level 5 of key 9?
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
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
The customer's order starts the process
Study the movement and motions of a worker or associate

48. What is level four of key 7?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
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
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

49. What is level 4 of key 10?
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.
Workers are conscientious about sticking to the work throughout the designated working areas.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Continuous improvement of person and process

50. What is level 4 of key 9?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in 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)
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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