Test your basic knowledge |

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 the purpose of operator flow charting?
Doubling productivity - Productivity = Output / TEE
Eliminate certain processes that produce or create waste.
Cycle time - work sequence - standard inventory
Preventative maintenance - Prevention maintenance - Corrective prevention

2. What is corrective maintenance?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Workers are conscientious about sticking to the work throughout the designated working areas.
You want to equalize your work loads in terms of your lot size - one-piece flow.

3. What is single file retrieval?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Study the movement and motions of a worker or associate
Work and break times are left to the workers' discretion
Anyone could find any file within one minute.

4. What is kaizen?
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
Can only be done when the machine is stopped or shut down.
Continuous improvement of person and process
Time it takes to make one unit

5. What is level two of key 8?
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.
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
Emphasize the connections between processes and full employee participation in improvement making

6. What is focused improvement?

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

7. What is cycle time?
Time it takes to make one unit
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Operators know they must keep their machines in good condition and eliminate the three evils.
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.

8. What is Industrial Engineering?
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Hands-on activity based on the facts - not opinion.
Video tape a person doing this so they can review what they're doing and improve.
Manufacturing value analysis

9. What is an external setup element?
Video tape a person doing this so they can review what they're doing and improve.
No one realizes that monitoring is waste - not work
Identifying problems before they cause breakdowns.
Can be done while the machine is still processing.

10. What is level three of key 8?
Factory employees begin setting up inter-process stores
You have to communicate! Coordinate where the output is going to be stored.
Executives do not understand the high rate of return linked to integrated improvement.
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.

11. What is level five of key 5?
Filming someone with a light on their finger so you can see the movements to better improve the design.
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
Knowledge - Job security - Safety - Simplicity
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

12. What is level five 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
Double capacity and the per unit production cost is 60% of the lower capacity option.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
To eliminate the big 3.

13. What is the purpose of Therblig analysis?
The available production time divided by the rate of customer demand
Helps you understand the facts as they are.
Emphasize the connections between processes and full employee participation in improvement making
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.

14. What is product flow charting?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Study the flow of a product through the various operations
One operator handling several machines or processes
Factory employees begin setting up inter-process stores

15. What is prevention maintenance?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Preventative maintenance - Prevention maintenance - Corrective prevention
Run the machines into the ground
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

16. What are the three key technical activities in a TPM program?
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.
Preventative maintenance - Prevention maintenance - Corrective prevention
The customer's order starts the process

17. What is autonomation (Jidoka)?
Double capacity and the per unit production cost is 60% of the lower capacity option.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Filming someone with a light on their finger so you can see the movements to better improve the design.

18. What is preventive maintenance?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Anyone could find any file within one minute.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.

19. What are the five components of TPM?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Filming someone with a light on their finger so you can see the movements to better improve the design.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

20. What is the 'Six-Tenths Rule'?
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
Video tape a person doing this so they can review what they're doing and improve.
Knowledge - Job security - Safety - Simplicity
Double capacity and the per unit production cost is 60% of the lower capacity option.

21. What is level four of key 6?
Time measuring
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Each section does its own thing; each workplace functions independently
Maintaining equipment

22. What is push production?

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

23. What is an internal setup element?
Operators know they must keep their machines in good condition and eliminate the three evils.
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.
Involving production employees in the total machine maintenance process.
Can only be done when the machine is stopped or shut down.

24. What is key #7?
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Zero monitor manufacturing
Identifying problems before they cause breakdowns.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

25. What did Frank Gilbreth do?
No one realizes that monitoring is waste - not work
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
Made the basic elements of human motion (therbligs)

26. What are the 6 Big Losses of TPM?
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
The customer's order starts the process
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 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'.

27. What is the main goal of MVA?
Involving production employees in the total machine maintenance process.
Doubling productivity - Productivity = Output / TEE
It's hard because it deals with attitudes of employees.
Can only be done when the machine is stopped or shut down.

28. What is operator flow charting?
Large scale improvement
You have to communicate! Coordinate where the output is going to be stored.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Study the movement and motions of a worker or associate

29. What is predictive maintenance?
Filming someone with a light on their finger so you can see the movements to better improve the design.
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.
Machines work together to prevent overproduction - it stops once it meets demands.

30. What is level 4 of key 10?
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Workers are conscientious about sticking to the work throughout the designated working areas.
The available production time divided by the rate of customer demand
Machines work together to prevent overproduction - it stops once it meets demands.

31. What is kaikaku?
Large scale improvement
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 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
Run the machines into the ground

32. What is the make/ship loop?
Inventory waste - Delay - Declining quality
Continuous improvement of person and process
Backorders create complacency.
Staying competitive with yesterday's products is difficult - if not impossible.

33. What is level 4 of key 9?
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
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.
Helps you understand the facts as they are.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

34. What is level three of key 5?
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.
Continuous improvement of person and process
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

35. What are the different types of motions required for performing an operation? (Type 1 motions)
Prevents equipment from breaking down or malfunctioning.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Involving production employees in the total machine maintenance process.

36. What is level two 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.
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.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Quick changeover studies begin; some employees are learning how to implement single changeover.

37. What is key 10?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Time control and commitment
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
No one realizes that monitoring is waste - not work

38. What is level three of key 6?
There is a shotgun approach to improvements; people have little concern for improving methods.
People have learned how to make systematic improvements at each process.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Contamination - inadequate lubrication - misoperation

39. What is level 5 of key 10?
Staying competitive with yesterday's products is difficult - if not impossible.
Factory employees begin setting up inter-process stores
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

40. What are the benefits of quick changeover for companies?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Maintaining equipment
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.

41. What is full work system?
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)
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.
Machines work together to prevent overproduction - it stops once it meets demands.
Study the flow of a product through the various operations

42. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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'.
Can only be done when the machine is stopped or shut down.
Study the movement and motions of a worker or associate

43. 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

44. Full work systems
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
Anyone could find any file within one minute.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.

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

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

46. What is the trouble with large-lot production?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Video tape a person doing this so they can review what they're doing and improve.
Backorders create complacency.
Inventory waste - Delay - Declining quality

47. What is level five of key 7?
Everyone understands the need for PM; PM has been implemented for the most important machines.
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.
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Continuous improvement of person and process

48. What is multi-process handling?
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
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.
Cycle time - work sequence - standard inventory

49. What is level 2 of key 10?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Morning pep talk meetings are held everyday
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

50. What are the three pillars of lean systems?
Industrial engineering methodologies
Continuous improvement of person and process
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