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 kaikaku?
Zero monitor manufacturing
Prevention maintenance - Predictive maintenance - Corrective maintenance - Preventative maintenance - Autonomous maintenance
Large scale improvement
Run the machines into the ground


2. What are the process improvement steps?
Continuous improvement of person and process
Run the machines into the ground
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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.


3. What is the make/ship loop?
Improving the performance of existing equipment or adapting new equipment to the manufacturing environment.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup 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'.
Backorders create complacency.


4. What are the flowcharting rules of construction?
Can be done while the machine is still processing.
Over 10% of changeover processes have become single changeovers; offices have achieved single changeover in retrieving documents and files.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs
People have learned how to make systematic improvements at each process.


5. What is autonomation (Jidoka)?
To eliminate the big 3.
People have learned how to make systematic improvements at each process.
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Time it takes to make one unit


6. What is the 'Six-Tenths Rule'?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
It controls the forward movement of work - is a visual means of communication - and enables workers to manage the shop floor.
Coupled manufacturing
Double capacity and the per unit production cost is 60% of the lower capacity option.


7. What are the 5 pillars of TPM?

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8. What has to be done to get to level two 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
Hands-on activity based on the facts - not opinion.
You have to communicate! Coordinate where the output is going to be stored.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


9. What is the purpose of video analysis?

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10. What is the main goal of MVA?
Can only be done when the machine is stopped or shut down.
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.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method
Doubling productivity - Productivity = Output / TEE


11. What is level one of key 7?
Prevents equipment from breaking down or malfunctioning.
No one realizes that monitoring is waste - not work
Maintaining equipment
Work is easier when it follows a steady rhythm; employees are performing value-adding work as soon as the start of the whistle blows.


12. What is the new product introduction loop?

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13. What is level one of key 6?
You have to communicate! Coordinate where the output is going to be stored.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
You want to equalize your work loads in terms of your lot size - one-piece flow.
There is a shotgun approach to improvements; people have little concern for improving methods.


14. What is level four of key 8?
Run the machines into the ground
Study the flow of a product through the various operations
Prevents equipment from breaking down or malfunctioning.
Clearly visable coupling points have been established throughout the factory; offices are seeing positive results from the fishbowl method


15. What is level four of key 5?
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
The customer's order starts the process
You have to communicate! Coordinate where the output is going to be stored.
Single changeover has been achieved on all machines currently in use; single file retrieval has been achieved in at least one office.


16. What is key 10?
Can only be done when the machine is stopped or shut down.
To eliminate the big 3.
Time control and commitment
Run the machines into the ground


17. What are the 6 Big Losses of TPM?
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
Anyone could find any file within one minute.
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Preliminary stage (Setup analysis) - Separate internal and external setup operations - Convert internal and external setup operations - Streamline all aspects of the setup operation


18. What is key #5?
Better quality - Faster delivery - Enhanced flexibility - Increased capacity - Lower cost
Hands-on activity based on the facts - not opinion.
Prevents equipment from breaking down or malfunctioning.
Quick changeover technology


19. What appears to be the primary metric in key 6?
Time measuring
To eliminate the big 3.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Quick changeover technology


20. What is the purpose of flowcharting?
Graphically capturing the steps in a process - Flowcharts with built-in intelligence
Determining the life expectancy of components in order to replace them at the optimum time.
Workers are conscientious about sticking to the work throughout the designated working areas.
Everyone recognizes that monitoring is waste


21. 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)
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
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.
Operators know they must keep their machines in good condition and eliminate the three evils.


22. What is the order processing and distribution loops?

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23. What is level 1 of key 10?

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24. What are the three pillars of lean systems?
Knowledge - Job security - Safety - Simplicity
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Maintain normal conditions - early discovery of abnormalities - and prompt response.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time


25. What is level five of key 5?
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
Operators know they must keep their machines in good condition and eliminate the three evils.
Single changeover is applied to all machines and all parts; working toward even shorter cycle-time changeover
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


26. What is the goal of motion study?
To eliminate the big 3.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Everyone recognizes that monitoring is waste
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.


27. What is level 5 of key 9?
Operators know they must keep their machines in good condition and eliminate the three evils.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Preventative maintenance - Prevention maintenance - Corrective prevention
Emphasize the connections between processes and full employee participation in improvement making


28. What are the functions and rules of kanban?
Study the movement and motions of a worker or associate
Using scheduled or planned maintenance to ensure the continuous - smooth operation of equipment.
Cycle time - work sequence - standard inventory
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


29. What is an external setup element?
Everyone understands the need for PM; PM has been implemented for the most important machines.
Cycle time - work sequence - standard inventory
Preventative maintenance - Prevention maintenance - Corrective prevention
Can be done while the machine is still processing.


30. What did Frank Gilbreth do?
Time measuring
Large scale improvement
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
Made the basic elements of human motion (therbligs)


31. What is key #6?
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.
Eliminate certain processes that produce or create waste.
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.


32. What is takt time?
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Each section does its own thing; each workplace functions independently
You want to equalize your work loads in terms of your lot size - one-piece flow.
The available production time divided by the rate of customer demand


33. What is level 2 of key 9?
Emphasize the connections between processes and full employee participation in improvement making
Everyone understands the need for PM; PM has been implemented for the most important machines.
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal
Workers are conscientious about sticking to the work throughout the designated working areas.


34. What is level two of key 5?
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.
TQM: total quality maintenance - TPM: total productive maintenance - JIT (Kanban): just in time
Quick changeover studies begin; some employees are learning how to implement single changeover.
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.


35. What is multi-process handling?
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
One operator handling several machines or processes
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.
Define boundaries - Left to right and top to bottom - Build in intelligence (people - time - distance - WIP) - Label inputs/ outputs


36. What is prevention maintenance?
Study the flow of a product through the various operations
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
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


37. What are the benefits of quick changeover for associates?
Knowledge - Job security - Safety - Simplicity
Study the movement and motions of a worker or associate
Anyone could find any file within one minute.
Work and break times are left to the workers' discretion


38. What are the three evils?
Giving the machine intelligence to make decisions. It means the meaning of management. Stopping the machine when there is trouble forces awareness on everyone.
Contamination - inadequate lubrication - misoperation
Can be done while the machine is still processing.
Study the flow of a product through the various operations


39. What is preventative maintenance?
Identifying problems before they cause breakdowns.
A focused equipment improvement program is deployed and monitored factory-wide; the overall equipment operating rate is 95% or higher.
Maintain normal conditions - early discovery of abnormalities - and prompt response.
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.


40. 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
Company-wide integration; all interdepartmental walls have been demolished so that goods and information can flow freely; a change-adaptive factory has been created.
Preventative maintenance - Prevention maintenance - Corrective prevention
Factory employees begin setting up inter-process stores


41. 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
Executives do not understand the high rate of return linked to integrated improvement.
Staying competitive with yesterday's products is difficult - if not impossible.
Run the machines into the ground


42. What is level 4 of key 9?
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
Determining the life expectancy of components in order to replace them at the optimum time.
All machines can operate during lunch without monitoring and many operators can handle two or more machines
Everyone understands and is committed to focused improvement; the focused improvement approach is being implemented in pursuit of the zero-breakdown goal


43. What is cycle time?
Value adding-assemble - disassemble - use Necessary-transport empty - grasp - transport loaded - release load - Unnecessary- reposition (due to poor arrangement - method) - inspect
Coupled manufacturing
Time it takes to make one unit
Involving production employees in the total machine maintenance process.


44. What is push production?

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45. What are the three key technical activities in a TPM program?
You have to communicate! Coordinate where the output is going to be stored.
Contamination - inadequate lubrication - misoperation
Preventative maintenance - Prevention maintenance - Corrective prevention
Time it takes to make one unit


46. What are the benefits of properly maintaining equipment?
Manufacturing value analysis
Labor-saving and efficiency-boosting improvements have enabled the factory to double its productivity.
Zero breakdowns and far few minor stoppages due to quality problems - material shortages - or changeover delays.
Time it takes to make one unit


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

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48. What are the steps in motion study?
Coupled manufacturing
Quick changeover studies begin; some employees are learning how to implement single changeover.
Define the problem - Discover the Big 3 - Eliminate the Big 3 - Evaluate the improved operation
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.


49. What is operator flow charting?
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.
Emphasize the connections between processes and full employee participation in improvement making
Helps you understand the facts as they are.
Study the movement and motions of a worker or associate


50. What is production leveling?
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
Each section does its own thing; each workplace functions independently
The factory now has almost zero monitoring time; the firmly established zero-monitoring campaign is also a zero-defects campaign
You want to equalize your work loads in terms of your lot size - one-piece flow.