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 3 of key 10?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Supervisors meet to work out time control issues
Determining the life expectancy of components in order to replace them at the optimum time.
Emphasize the connections between processes and full employee participation in improvement making


2. What is preventive maintenance?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Work and break times are left to the workers' discretion


3. What are the benefits of properly maintaining equipment?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
To eliminate the big 3.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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


4. What is the main goal of MVA?
There is a shotgun approach to improvements; people have little concern for improving methods.
Hands-on activity based on the facts - not opinion.
Doubling productivity - Productivity = Output / TEE
Machines work together to prevent overproduction - it stops once it meets demands.


5. What is level four of key 7?
Supervisors meet to work out time control issues
Run the machines into the ground
Everyone understands the need for PM; PM has been implemented for the most important machines.
All machines can operate during lunch without monitoring and many operators can handle two or more machines


6. What does kanban do?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Cycle time - work sequence - standard inventory
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
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)


7. What is level one of key 6?
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.
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.
There is a shotgun approach to improvements; people have little concern for improving methods.


8. What is level three of key 6?
Study the movement and motions of a worker or associate
Hands-on activity based on the facts - not opinion.
Anyone could find any file within one minute.
People have learned how to make systematic improvements at each process.


9. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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)
Executives do not understand the high rate of return linked to integrated improvement.
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


10. What is level 4 of 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
Workers are conscientious about sticking to the work throughout the designated working areas.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Time it takes to make one unit


11. What are the three evils?
Contamination - inadequate lubrication - misoperation
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
Study the movement and motions of a worker or associate
Coupled manufacturing


12. What is level five of key 8?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Cycle time - work sequence - standard inventory


13. What is the trouble with large-lot production?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
The available production time divided by the rate of customer demand
Knowledge - Job security - Safety - Simplicity
Inventory waste - Delay - Declining quality


14. What is level five of key 5?
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Maintaining equipment


15. What is level two of key 7?
Can be done while the machine is still processing.
Everyone recognizes that monitoring is waste
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
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.


16. What are the steps in motion study?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Morning pep talk meetings are held everyday
Everyone recognizes that monitoring is waste
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation


17. What are the basic steps in a traditional changeover?
Time control and commitment
Helps you understand the facts as they are.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Double capacity and the per unit production cost is 60% of the lower capacity option.


18. What are the benefits of quick changeover for companies?
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost


19. What is full work system?
Machines work together to prevent overproduction - it stops once it meets demands.
To eliminate the big 3.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Backorders create complacency.


20. 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
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Doubling productivity - Productivity = Output / TEE
Study the flow of a product through the various operations


21. What is 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.
Run the machines into the ground
Maintaining equipment
Supervisors meet to work out time control issues


22. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Large scale improvement
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Quick changeover studies begin; some employees are learning how to implement single changeover.


23. 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.
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.
Double capacity and the per unit production cost is 60% of the lower capacity option.
It's hard because it deals with attitudes of employees.


24. What is prevention maintenance?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.


25. What is the make/ship loop?
Each section does its own thing; each workplace functions independently
Backorders create complacency.
Study the flow of a product through the various operations
Contamination - inadequate lubrication - misoperation


26. What is level three of key 8?
Factory employees begin setting up inter-process stores
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
You have to communicate! Coordinate where the output is going to be stored.
Workers are conscientious about sticking to the work throughout the designated working areas.


27. What is the value of TPM?
Study the flow of a product through the various operations
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
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.


28. What is preventative maintenance?
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
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
Preventative maintenance - Prevention maintenance - Corrective prevention


29. What is takt time?
The available production time divided by the rate of customer demand
Study the movement and motions of a worker or associate
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'.


30. What are the 6 Big Losses of TPM?
Run the machines into the ground
Emphasize the connections between processes and full employee participation in improvement making
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
The available production time divided by the rate of customer demand


31. 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
To eliminate the big 3.
Executives do not understand the high rate of return linked to integrated improvement.
Cycle time - work sequence - standard inventory


32. What is cycle time?
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
Time it takes to make one unit
Everyone recognizes that monitoring is waste
Large scale improvement


33. What are the motions that slow down Type 1 motions?
You want to equalize your work loads in terms of your lot size - one-piece flow.
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)
The customer's order starts the process
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


34. At level three of key 6 - what is the methodology employees have been trained to use?
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
Industrial engineering methodologies
Operators know they must keep their machines in good condition and eliminate the three evils.
Large scale improvement


35. What is an internal setup element?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Contamination - inadequate lubrication - misoperation
Can only be done when the machine is stopped or shut down.
Each section does its own thing; each workplace functions independently


36. What is key #6?
Involving production employees in the total machine maintenance process.
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
Manufacturing value analysis
Can only be done when the machine is stopped or shut down.


37. What is focused improvement?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


38. What is key 10?
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
Made the basic elements of human motion (therbligs)
Machines work together to prevent overproduction - it stops once it meets demands.


39. What is the purpose of video analysis?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


40. What is level four of key 6?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Everyone recognizes that monitoring is waste


41. What is the new product introduction loop?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


42. What are the different types of motions required for performing an operation? (Type 1 motions)
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Coupled manufacturing
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
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


43. What is level two of key 5?
Quick changeover studies begin; some employees are learning how to implement single changeover.
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.
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


44. What is level 5 of key 10?
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
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Emphasize the connections between processes and full employee participation in improvement making
Time measuring


45. What is the purpose of Therblig analysis?
Helps you understand the facts as they are.
Made the basic elements of human motion (therbligs)
Knowledge - Job security - Safety - Simplicity
Hands-on activity based on the facts - not opinion.


46. What is kaikaku?
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Executives do not understand the high rate of return linked to integrated improvement.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Large scale improvement


47. What is level 4 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 and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Work and break times are left to the workers' discretion
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


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

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


49. What is the order processing and distribution loops?

Warning: Invalid argument supplied for foreach() in /var/www/html/basicversity.com/show_quiz.php on line 183


50. What is level one of key 5?
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
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Study the movement and motions of a worker or associate