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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 corrective maintenance?
The customer's order starts the process
Contamination - inadequate lubrication - misoperation
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.
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

2. What is level 3 of key 10?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Machines work together to prevent overproduction - it stops once it meets demands.
Everyone recognizes that monitoring is waste
Supervisors meet to work out time control issues

3. What are the three pillars of lean systems?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Workers are conscientious about sticking to the work throughout the designated working areas.
No one realizes that monitoring is waste - not work

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

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5. 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
Executives do not understand the high rate of return linked to integrated improvement.
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.

6. What is level three of key 6?
Helps you understand the facts as they are.
People have learned how to make systematic improvements at each process.
Cycle time - work sequence - standard inventory
Large scale improvement

7. What are the three evils?
One operator handling several machines or processes
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Contamination - inadequate lubrication - misoperation
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

8. What is an internal setup element?
Factory employees begin setting up inter-process stores
Can only be done when the machine is stopped or shut down.
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)
Time control and commitment

9. What is level one of key 7?
No one realizes that monitoring is waste - not work
Prevents equipment from breaking down or malfunctioning.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Morning pep talk meetings are held everyday

10. What are the three principles of prevention?
Each section does its own thing; each workplace functions independently
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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.

11. What does manufacturing value analysis do?
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
The customer's order starts the process
Helps you understand the facts as they are.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

12. What are the benefits of properly maintaining equipment?
Backorders create complacency.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
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.

13. What is preventive maintenance?
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.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
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.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

14. What is kaizen?
Continuous improvement of person and 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.
One operator handling several machines or processes
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

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

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16. What is pull production?
Workers are conscientious about sticking to the work throughout the designated working areas.
Operators know they must keep their machines in good condition and eliminate the three evils.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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

17. What is the purpose of Chronocyclegraphic analysis?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Continuous improvement of person and 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.

18. What are the 5 pillars of TPM?

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19. 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.
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.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
One operator handling several machines or processes

20. 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.
Eliminate certain processes that produce or create waste.
Knowledge - Job security - Safety - Simplicity
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.

21. What is level three of key 7?
Industrial engineering methodologies
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
Time measuring
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

22. What is the value of TPM?
Workers are conscientious about sticking to the work throughout the designated working areas.
Study the flow of a product through the various operations
The available production time divided by the rate of customer demand
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.

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

24. What are the benefits of quick changeover for companies?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Workers are conscientious about sticking to the work throughout the designated working areas.
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

25. What are the three elements of the standard work sheet?
Cycle time - work sequence - standard inventory
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

26. What is the order processing and distribution loops?

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27. What is operator flow charting?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Study the movement and motions of a worker or associate

28. What is takt 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'.
The available production time divided by the rate of customer demand
Doubling productivity - Productivity = Output / TEE
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

29. What are the functions and rules of kanban?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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
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

30. What is key #8?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Determining the life expectancy of components in order to replace them at the optimum time.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Coupled manufacturing

31. What is level one 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
Each section does its own thing; each workplace functions independently
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 factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

32. What is key #6?
Manufacturing value analysis
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
Zero monitor manufacturing
Preventative maintenance - Prevention maintenance - Corrective prevention

33. What are the five components of TPM?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
The available production time divided by the rate of customer demand
Preventative maintenance - Prevention maintenance - Corrective prevention
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

34. What is the purpose of operator flow charting?
Morning pep talk meetings are held everyday
Can be done while the machine is still processing.
Involving production employees in the total machine maintenance process.
Eliminate certain processes that produce or create waste.

35. 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.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Knowledge - Job security - Safety - Simplicity
Time measuring

36. What is key #5?
Quick changeover technology
Filming someone with a light on their finger so you can see the movements to better improve the design.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Doubling productivity - Productivity = Output / TEE

37. What does TPM do?
Prevents equipment from breaking down or malfunctioning.
Study the movement and motions of a worker or associate
Industrial engineering methodologies
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

38. What is the purpose of Therblig analysis?
Doubling productivity - Productivity = Output / TEE
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.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Helps you understand the facts as they are.

39. What are the motions that slow down Type 1 motions?
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)
Supervisors meet to work out time control issues
Time it takes to make one unit
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

40. What is level one of key 6?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
There is a shotgun approach to improvements; people have little concern for improving methods.
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.
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.

41. What is level two of key 5?
Quick changeover studies begin; some employees are learning how to implement single changeover.
Cycle time - work sequence - standard inventory
Prevents equipment from breaking down or malfunctioning.
Knowledge - Job security - Safety - Simplicity

42. What is product flow charting?
Manufacturing value analysis
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 flow of a product through the various operations
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

43. What is Industrial Engineering?
Hands-on activity based on the facts - not opinion.
Maintaining equipment
The available production time divided by the rate of customer demand
Made the basic elements of human motion (therbligs)

44. What is preventative maintenance?
Operators know they must keep their machines in good condition and eliminate the three evils.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Quick changeover technology
Identifying problems before they cause breakdowns.

45. What is level four 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.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Made the basic elements of human motion (therbligs)
Contamination - inadequate lubrication - misoperation

46. What is key #7?
Knowledge - Job security - Safety - Simplicity
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.
Zero monitor manufacturing
You want to equalize your work loads in terms of your lot size - one-piece flow.

47. 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
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Morning pep talk meetings are held everyday

48. What is autonomous maintenance?
Manufacturing value analysis
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
Involving production employees in the total machine maintenance process.
Morning pep talk meetings are held everyday

49. What is level one of key 5?
Cycle time - work sequence - standard inventory
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Executives do not understand the high rate of return linked to integrated improvement.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

50. What is cycle time?
Time control and commitment
Helps you understand the facts as they are.
To eliminate the big 3.
Time it takes to make one unit