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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 are the three evils?
Quick changeover technology
Video tape a person doing this so they can review what they're doing and improve.
Contamination - inadequate lubrication - misoperation
You want to equalize your work loads in terms of your lot size - one-piece flow.

2. What is the make/ship loop?
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.
Backorders create complacency.
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Can only be done when the machine is stopped or shut down.

3. What are the steps in motion study?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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)
Inventory waste - Delay - Declining quality
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.

4. What are the five components of TPM?
Operators know they must keep their machines in good condition and eliminate the three evils.
Can be done while the machine is still processing.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

5. What is preventive maintenance?
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
Made the basic elements of human motion (therbligs)
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

6. What is prevention maintenance?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
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.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

7. 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
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Supervisors meet to work out time control issues
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.

8. What is level three of key 8?
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
It's hard because it deals with attitudes of employees.
Double capacity and the per unit production cost is 60% of the lower capacity option.
Factory employees begin setting up inter-process stores

9. What is level two of key 8?
Emphasize the connections between processes and full employee participation in improvement making
Study the flow of a product through the various operations
Executives do not understand the high rate of return linked to integrated improvement.
Can only be done when the machine is stopped or shut down.

10. What are the flowcharting rules of construction?
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
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Video tape a person doing this so they can review what they're doing and improve.
Supervisors meet to work out time control issues

11. 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
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Inventory waste - Delay - Declining quality

12. What is level one of key 8?
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.
Each section does its own thing; each workplace functions independently
Knowledge - Job security - Safety - Simplicity
Large scale improvement

13. What are the motions that slow down Type 1 motions?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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)
Run the machines into the ground
Can be done while the machine is still processing.

14. What are the different types of motions required for performing an operation? (Type 1 motions)
Determining the life expectancy of components in order to replace them at the optimum time.
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
You have to communicate! Coordinate where the output is going to be stored.
Machines work together to prevent overproduction - it stops once it meets demands.

15. What is the main goal of MVA?
Doubling productivity - Productivity = Output / TEE
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
The customer's order starts the process
You have to communicate! Coordinate where the output is going to be stored.

16. What is the trouble with large-lot production?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Made the basic elements of human motion (therbligs)
Inventory waste - Delay - Declining quality

17. What are the three key technical activities in a TPM program?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Emphasize the connections between processes and full employee participation in improvement making
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Preventative maintenance - Prevention maintenance - Corrective prevention

18. What is level four of key 7?
Time control and commitment
To eliminate the big 3.
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

19. What is operator flow charting?
Anyone could find any file within one minute.
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
Study the movement and motions of a worker or associate
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign

20. What is level three of key 5?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Prevents equipment from breaking down or malfunctioning.
Identifying problems before they cause breakdowns.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.

21. 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
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.
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

22. What are the benefits of quick changeover for companies?
No one realizes that monitoring is waste - not work
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'.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost

23. What is level 3 of key 9?
Study the flow of a product through the various operations
Prevents equipment from breaking down or malfunctioning.
Operators know they must keep their machines in good condition and eliminate the three evils.
Study the movement and motions of a worker or associate

24. What is an internal setup element?
Large scale improvement
Can only be done when the machine is stopped or shut down.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Can be done while the machine is still processing.

25. What is level 1 of key 9?
Run the machines into the ground
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in 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
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.

26. What is level four of key 5?
Study the movement and motions of a worker or associate
Industrial engineering methodologies
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
Maintaining equipment

27. What are the steps in Shingo's changeover system?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Inventory waste - Delay - Declining quality
Staying competitive with yesterday's products is difficult - if not impossible.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.

28. What is full work system?
Hands-on activity based on the facts - not opinion.
Machines work together to prevent overproduction - it stops once it meets demands.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
No one realizes that monitoring is waste - not work

29. What is predictive maintenance?
Prevents equipment from breaking down or malfunctioning.
Determining the life expectancy of components in order to replace them at the optimum time.
Cycle time - work sequence - standard inventory
Doubling productivity - Productivity = Output / TEE

30. What is multi-process handling?
Large scale 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
One operator handling several machines or processes
Executives do not understand the high rate of return linked to integrated improvement.

31. What are the motions that do not perform an operation?
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Eliminate certain processes that produce or create waste.
The customer's order starts the process
Inventory waste - Delay - Declining quality

32. What is the purpose of flowcharting?
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
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
Industrial engineering methodologies

33. What are the three principles of prevention?
Preventative maintenance - Prevention maintenance - Corrective prevention
People have learned how to make systematic improvements at each process.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover

34. What is level 4 of key 10?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Workers are conscientious about sticking to the work throughout the designated working areas.
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

35. What is single file retrieval?
Work and break times are left to the workers' discretion
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Anyone could find any file within one minute.
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.

36. What is focused improvement?

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37. What is the purpose of Cyclegraphic analysis?
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
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

38. What are the 6 Big Losses of TPM?
Identifying problems before they cause breakdowns.
Backorders create complacency.
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
Preventative maintenance - Prevention maintenance - Corrective prevention

39. What is the goal of motion study?
To eliminate the big 3.
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Machines work together to prevent overproduction - it stops once it meets demands.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

40. What is key #9?
Machines work together to prevent overproduction - it stops once it meets demands.
Maintaining equipment
Preventative maintenance - Prevention maintenance - Corrective prevention
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary

41. What is key #8?
Industrial engineering methodologies
Time it takes to make one unit
Coupled manufacturing
No one realizes that monitoring is waste - not work

42. What is key #5?
Morning pep talk meetings are held everyday
Quick changeover technology
Hands-on activity based on the facts - not opinion.
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.

43. What is the value of TPM?
Study the movement and motions of a worker or associate
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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.
Maintaining equipment

44. What is level 3 of key 10?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Supervisors meet to work out time control issues
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.

45. What is production leveling?
Industrial engineering methodologies
You want to equalize your work loads in terms of your lot size - one-piece flow.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Each section does its own thing; each workplace functions independently

46. What is level five of key 6?
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
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
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
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs

47. Full work systems
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
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)
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

48. What is key #6?
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Manufacturing value analysis
Work and break times are left to the workers' discretion
It's hard because it deals with attitudes of employees.

49. What is an external setup element?
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.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
Can be done while the machine is still processing.
Made the basic elements of human motion (therbligs)

50. What does TPM do?
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Involving production employees in the total machine maintenance process.
The available production time divided by the rate of customer demand
Prevents equipment from breaking down or malfunctioning.