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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 benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Designing or selecting equipment that will run with minimal maintenance and is easy to service when necessary
Contamination - inadequate lubrication - misoperation
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)

2. What are the steps in motion study?
Morning pep talk meetings are held everyday
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Machines work together to prevent overproduction - it stops once it meets demands.
Quick changeover technology

3. What did Frank Gilbreth do?
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Made the basic elements of human motion (therbligs)
You have to communicate! Coordinate where the output is going to be stored.

4. What is the value of TPM?
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time

5. What are the process improvement steps?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
One operator handling several machines or processes
Doubling productivity - Productivity = Output / TEE
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

6. 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
It's hard because it deals with attitudes of employees.
Doubling productivity - Productivity = Output / TEE
Eliminate certain processes that produce or create waste.

7. What is level 3 of key 9?
Preventative maintenance - Prevention maintenance - Corrective prevention
Executives do not understand the high rate of return linked to integrated improvement.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.
Operators know they must keep their machines in good condition and eliminate the three evils.

8. What is level five of key 5?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
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

9. What is the new product introduction loop?

10. What is level four of key 5?
Time control and commitment
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
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

11. What are the motions that slow down Type 1 motions?
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
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'.
Continuous improvement of person and process
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)

12. Full work systems
Can be done while the machine is still processing.
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
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Staying competitive with yesterday's products is difficult - if not impossible.

13. What is level 2 of key 9?
Work and break times are left to the workers' discretion
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
Everyone understands the need for PM; PM has been implemented for the most important machines.
One operator handling several machines or processes

14. What is level three of key 5?
Contamination - inadequate lubrication - misoperation
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Each section does its own thing; each workplace functions independently

15. What is full work system?
Filming someone with a light on their finger so you can see the movements to better improve the design.
Machines work together to prevent overproduction - it stops once it meets demands.
Each section does its own thing; each workplace functions independently
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance

16. What is level 5 of key 9?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
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.
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.

17. What is level two of key 7?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
No one realizes that monitoring is waste - not work
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Everyone recognizes that monitoring is waste

18. What is predictive maintenance?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
Determining the life expectancy of components in order to replace them at the optimum time.

19. What are the basic steps in a traditional changeover?
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Executives do not understand the high rate of return linked to integrated improvement.

20. What is key #8?
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Coupled manufacturing
Backorders create complacency.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)

21. What does manufacturing value analysis do?
Continuous improvement of person and process
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
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Doubling productivity - Productivity = Output / TEE

22. What is level two of key 8?
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
Emphasize the connections between processes and full employee participation in improvement making
Time control and commitment
Operators know they must keep their machines in good condition and eliminate the three evils.

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

24. What does kanban do?
Staying competitive with yesterday's products is difficult - if not impossible.
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
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.
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.

25. What does TPM do?
Prevents equipment from breaking down or malfunctioning.
Morning pep talk meetings are held everyday
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Doubling productivity - Productivity = Output / TEE

26. What is level five of key 6?
The improvement-making process is systematic and is implemented repeatedly; the manufacturing system is promptly adaptive to changes in product design and production volume.
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Backorders create complacency.

27. What are the 5 pillars of TPM?

28. What is level 3 of key 10?
Supervisors meet to work out time control issues
Double capacity and the per unit production cost is 60% of the lower capacity option.
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
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.

29. What is key #9?
Maintaining equipment
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.
People have learned how to make systematic improvements at each process.

30. What is single file retrieval?
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
Anyone could find any file within one minute.
Systematic improvement making has begun at each process; time values are part of a systematic - quantified approach.

31. What is level five of key 8?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
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

32. What is key #7?
Each section does its own thing; each workplace functions independently
Zero monitor manufacturing
You have to communicate! Coordinate where the output is going to be stored.
Continuous improvement of person and process

33. What is operator flow charting?
Contamination - inadequate lubrication - misoperation
Inventory waste - Delay - Declining quality
To eliminate the big 3.
Study the movement and motions of a worker or associate

34. What are the motions that do not perform an operation?
Coupled manufacturing
Identifying problems before they cause breakdowns.
Due to poor planning - timing - and/or method. All cost and should be eliminated. (rest - plan - unavoidable delay - avoidable delay)
Can be done while the machine is still processing.

35. What is level one of key 6?
Video tape a person doing this so they can review what they're doing and improve.
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
There is a shotgun approach to improvements; people have little concern for improving methods.
Maintain normal conditions - early discovery of abnormalities - and prompt response.

36. What is the goal of motion study?
Coupled manufacturing
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
To eliminate the big 3.
Double capacity and the per unit production cost is 60% of the lower capacity option.

37. What appears to be the primary metric in key 6?
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.
Time measuring
Preparation - Removing and mounting - Measurements - settings - and calibrations - Trial runs and adjustments
No one realizes that monitoring is waste - not work

38. What is the purpose of operator flow charting?
Coupled manufacturing
Eliminate certain processes that produce or create waste.
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 customer's order starts the process

39. What is production leveling?
You want to equalize your work loads in terms of your lot size - one-piece flow.
Quick changeover technology
Determining the life expectancy of components in order to replace them at the optimum time.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method

40. What has to be done to get to level two of key 8?
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
You have to communicate! Coordinate where the output is going to be stored.

41. What is the order processing and distribution loops?

42. At level three of key 6 - what is the methodology employees have been trained to use?
People mistakenly think that increasing lot sizes is a good way to reduce changeover time.
Zero monitor manufacturing
Industrial engineering methodologies
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect

43. What are the benefits of quick changeover for companies?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Helps you understand the facts as they are.
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'.
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.

44. What is level one of key 7?
Emphasize the connections between processes and full employee participation in improvement making
Can be done while the machine is still processing.
No one realizes that monitoring is waste - not work
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.

45. What is level 2 of key 10?
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
Morning pep talk meetings are held everyday
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Video tape a person doing this so they can review what they're doing and improve.

46. What is the purpose of video analysis?

47. What is push production?

48. What is level four of key 6?
Determining the life expectancy of components in order to replace them at the optimum time.
You have to communicate! Coordinate where the output is going to be stored.
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
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 are the 6 Big Losses of TPM?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
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'.
Maintaining equipment
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

50. What are the three evils?
Double capacity and the per unit production cost is 60% of the lower capacity option.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
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.
Contamination - inadequate lubrication - misoperation